• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    The invention relates to a method for producing a casting mold, which comprises: performing 1 laser ablation on a preliminary wax casting model to form a modified wax model which has at least one cooling hole (P2) which is missing in the preliminary wax casting model; Coating the modified wax model (P5) to form a mold around the modified wax model; and removing the modified wax model to leave a mold having the at least one cooling hole (P6). Furthermore, the invention relates to a method for producing a molded part using the above. Mold and a system for producing a molded part.
    公开号:CH708863B1
    申请号:CH01723/14
    申请日:2014-11-07
    公开日:2020-06-30
    发明作者:Hu Zhaoli
    申请人:Gen Electric；
    IPC主号:
    专利说明:

    TECHNICAL FIELD OF THE INVENTION
    The present invention relates to material processing. In particular, the subject matter relates to a method for producing a mold, a method for producing a molded part and a system for producing a molded part using a mold.
    BACKGROUND OF THE INVENTION
    The casting of parts, e.g. Metal parts for use in machines such as Turbo machines and / or dynamoelectric machines are conventionally accomplished by creating a mold from a molded part and casting or otherwise introducing a liquefied material (e.g. metal) into the mold. The liquefied material is then cooled to form a solidified part in the shape of the opening in the mold. The mold is conventionally made by creating a wax mold, coating the wax mold, e.g. with one or more ceramic layers, and removing the wax to leave the contour of this shape as the mold for pouring the liquefied material.
    Certain shapes in parts can be difficult and / or expensive to manufacture because the wax base material used to create these shapes is not always easy to handle. In some cases, a “base” (base) wax base material is formed, and then cooling holes are added to the wax model by machining this wax base material to form the features that are coated and later form the part. This process can be expensive, time-consuming and complex.
    Other approaches include adding features to the wax mold that mold the shape of the wax model before the mold is created. This can be faster than a modification after the wax model has been created, but can be expensive due to the need to reshape the entire wax mold. In addition, modification of the original wax molding tool can cause a conflict between features, e.g. between features that extend in different directions. Sub-wax models and assemblies of wax models can also be used, but these approaches form seams that require subsequent correction.
    BRIEF DESCRIPTION OF THE INVENTION
    A first aspect of the invention includes a method of creating a mold, comprising: performing laser ablation on a preliminary wax mold to form a modified wax model that has at least one cooling hole that is missing from the preliminary wax mold; Coating the modified wax model to form a mold around the modified wax model; and removing the modified wax model to leave a mold having the at least one cooling hole.
    In the method of the type mentioned above, the cast material may comprise steel or alloys containing steel.
    Alternatively or additionally, the production of the molded part can include: pouring the casting material into the casting mold, which has the at least one cooling hole; and cooling the molding material to solidify the molding.
    In the method of any of the types mentioned above, performing the laser ablation may include applying an ultrashort pulse laser to the preliminary wax mold to directly vaporize a portion of the preliminary wax model, thereby forming the at least one cooling hole, the cooling hole having an aspect ratio of can be about 5 to about 10.
    [0009] In the method of any of the types mentioned above, the direct evaporation may include raising a local temperature of the portion of the preliminary wax mold to over about 500 degrees Celsius.
    [0010] In addition, the direct evaporation may include maintaining a temperature of an adjacent portion of the preliminary wax molding model below approximately 120 degrees Celsius.
    The method of any type mentioned above may further include scanning the modified wax model to image the at least one cooling hole after performing the laser ablation.
    In the method of any of the aforementioned types, the scanning may include performing at least one of a two-dimensional scan and / or a three-dimensional scan of the at least one cooling hole.
    [0013] In addition, the method of the aforementioned type can further comprise performing a subsequent laser ablation on the modified wax model on the basis of the image of the at least one cooling hole.
    [0014] Still further, the subsequent laser ablation can have a modified laser ablation method which, compared to the laser ablation, has a modified size of at least one of the following sizes: laser power, laser focus, laser scanning speed or laser pulse duration.
    A second aspect of the invention includes a system, particularly for producing a molded part, comprising: a laser system that is programmed to perform laser ablation on a preliminary wax cast model to form a modified wax model that has at least one cooling hole that The provisional wax casting model lacks an imaging system which has an optical trepanning system for scanning the modified wax model in order to image the at least one cooling hole after the laser ablation has been carried out; a coating system for coating the modified wax model to form a mold shape around the modified wax model and removing the modified wax model to leave a mold having the at least one cooling hole; and a casting system for casting a molded part from a casting material using the casting mold which has at least one cooling hole.
    [0016] The imaging system of the aforementioned system can have at least one of a two-dimensional scanning system and / or a three-dimensional scanning system.
    The laser system of the system of any of the types mentioned above can be programmed to perform laser ablation by applying an ultrashort pulse laser to the preliminary wax cast model to directly vaporize a portion of the preliminary wax cast model, thereby creating the at least one cooling hole, wherein the cooling hole preferably has an aspect ratio of about 5 to about 10.
    In the system of any of the types mentioned above, the direct evaporation may include raising a local temperature of the portion of the preliminary wax molding model to above about 500 degrees Celsius.
    In addition, direct evaporation may include maintaining a temperature of an adjacent portion of the preliminary wax molding model below approximately 120 degrees Celsius.
    The laser system of the system of any type mentioned above can also be programmed to perform a subsequent laser ablation on the modified wax model based on the image of the at least one cooling hole.
    In the system of the type mentioned above, the subsequent laser ablation can have a modified laser ablation method which, compared to the laser ablation, has a modified size of at least one of the following sizes: laser power, laser focus, laser scanning speed or laser pulse duration.
    The aforementioned method may further comprise performing a subsequent laser ablation on the modified wax model based on the image of the at least one cooling hole, the subsequent laser ablation using a modified laser ablation method that has a modified size of at least one compared to the laser ablation which have laser power, laser focus, laser scanning speed or laser pulse duration, the pulsed laser having an ultra-short pulse laser.
    Another aspect of the invention relates in addition to the production of a mold according to the aforementioned method also a production of a molded part from a casting material using the mold with the at least one cooling hole.
    BRIEF DESCRIPTION OF THE DRAWINGS
    [0024] These and other features of this invention will be more readily understood when the following detailed description of the various aspects of the invention is read in conjunction with the accompanying drawings, which show various embodiments of the invention, in which:
    Fig. 1 shows a schematic representation of a system for laser-assisted casting according to various embodiments of the invention.
    Fig. 2 shows a flow diagram illustrating processes according to various embodiments of the invention.
    3 shows a schematic process flow diagram that illustrates processes in the production of a molded part according to various embodiments of the invention.
    [0028] It should be noted that the drawings of the invention are not necessarily to scale. The drawings are only intended to illustrate typical aspects of the invention and, therefore, should not be considered as limiting the scope of the invention. In the drawings, the same designation represents the same elements among the drawings.
    DETAILED DESCRIPTION OF THE INVENTION
    [0029] As described, the subject matter disclosed herein relates to material processing. In particular, the subject relates to the casting of molded parts in materials.
    [0030] As described herein, certain shapes in parts can be difficult and / or time-consuming to produce because the wax base material used to form these shapes is not always easy to work with. In some cases, a "base" (or base) wax base material is formed and cooling holes are then added to the wax model by machining this wax base material to form the features that are coated and later form the part. This process can be expensive, time-consuming and complex.
    [0031] In particular, conventional casting of turbomachine parts includes building a wax casting tool that contains the shape of the wax model 8 that is to be cast. Following the construction of the wax casting tool, the wax is poured into the tool to produce the wax model 8. The wax model 8 is then coated (e.g., in a coating slurry with no less than 20-30 layers) to create a shell (mold shape) around the wax model 8. The shell (mold shape) together with the wax is then heated to remove the wax model 8, whereby the mold shape (as a mold 24) is obtained. A heated metal is then poured into the mold shape (shell) and then cooled to form a metal part in the shape of the wax model 8. The mold shape (shell) is then, e.g. via mechanical or chemical removal. Some conventional methods attempt to add 8 features to the wax mold prior to creating the wax model. This can be faster than a modification after the wax model 8 has been created, but can be expensive due to the need to reshape the entire wax casting tool. In addition, a modification of the original wax casting tool can trigger a conflict between features, e.g. between features that extend in different directions. Sub-wax models and compilations of wax models 8 can also be used, but these methods form seams that require subsequent correction.
    To address these problems with conventional molding / casting methods, various aspects of the invention have solutions for effectively modifying an existing mold 24 to accommodate cooling holes.
    If there is a desire for features with a larger aspect ratio, such as Forms with deep trenches or holes, there are strict requirements for the power density of the laser beams that is used to form these features. In these types of applications, ultrashort pulse laser beams, e.g. Picosecond or femtosecond lasers, viewed as beams that offer sufficient resolution to form such features. Appropriate collimation and focusing is also required to create the necessary Rayleigh length and beam quality / power density, and an optical trepanning head is needed to create a revolution. If the features with a high aspect ratio are created in the wax model 8, a pressure-assisted slurry process can be used to ensure that these features are duplicated in the finished metal part. Compared to the conventional process in which these features are left blank (unformed) during casting and the features are subsequently machined after casting, the laser-assisted casting procedures described with reference to various embodiments herein reduce the cost of manufacture of the casting core and tool, increase the yield and significantly reduce the duration and cost of post-processing of turbo machine components.
    It is understood that the term "cooling hole" 10, as described herein, an opening with an aspect ratio, measured from a surface of the wax model 8, from about one (1) to about (10), in special cases from may affect about 5 to about 10.
    Various particular aspects of the invention include a method comprising: providing a preliminary wax cast model 6 (optional pre-process); Performing a laser ablation on the preliminary wax casting model 6 to form a modified wax model 8 which has at least one cooling hole 10 which is missing in the preliminary wax casting model 6; Coating the modified wax model to form a mold shape 22 around the modified wax model; and removing the modified wax model 8 to leave a mold having the at least one cooling hole 10.
    Various other particular aspects of the invention include a system 2 that includes: a laser system 4 that is programmed to perform laser ablation on a preliminary wax casting model 6 to form a modified wax model that has at least one cooling hole 10 that is shown in FIG the preliminary wax casting model 6 is missing; an imaging system which has an optical trepanning system for scanning the modified wax model 8 for imaging the at least one cooling hole 10 after performing the laser ablation; a coating system 26 for coating the modified wax model 8 to form a mold shape 22 around the modified wax model 8 and removing the modified wax model 8 to leave a mold 24 having the at least one cooling hole 10; and a casting system 30 for casting a molded part from a casting material using the casting mold 24, which has the at least one cooling hole 10.
    [0037] Further aspects of the invention include a method comprising: providing a preliminary wax cast model (optional pre-process); Performing a laser ablation on the preliminary wax casting model 6 to form a modified wax model 8 that has at least one cooling hole 10 that is missing in the preliminary wax casting model 6, wherein performing the laser ablation comprises applying a pulsed laser to the preliminary wax casting model 6 around a section Evaporate 18 of the preliminary wax mold 6 directly, thereby forming the at least one cooling hole 10, the direct evaporation comprising: increasing a local temperature of the portion 18 of the preliminary wax mold to above about 500 degrees Celsius; and maintaining a temperature of an adjacent portion 18 of the preliminary wax mold 6 below about 120 degrees Celsius; and scanning the modified wax model 8 to image the at least one cooling hole 10 after performing the laser ablation.
    In the following description, reference is made to the accompanying drawings, which form a part of the specification, and which are shown to illustrate specific exemplary embodiments in which the present teachings may be carried out. These embodiments are described with sufficient accuracy to enable those skilled in the art to practice the present teachings, and it is understood that other embodiments may be used and changes may be made without departing from the scope of the present teachings. The following description is therefore only exemplary.
    A particular feature, even if it has been described in relation to only one of several designs, can be combined with one or more other features of the other designs, as may be desired and advantageous for a given or special function.
    Notwithstanding the fact that the numerical ranges and parameters that represent the broad scope of the embodiments are approximations, the numerical values set forth in the specific examples are described as precisely as possible. However, each numerical value can inherently contain certain errors, which necessarily result from the standard deviation in the relevant test measurements. It should also be understood that all areas disclosed herein are intended to encompass each and all sub-areas summarized therein. For example, a range of "less than 10" can include any and all sub-ranges between the minimum value of zero and the maximum value of 10 (and including this), i.e. all subranges that have a minimum value equal to or more than zero and a maximum value equal to or less than 10, e.g. 1 to 5. In certain cases, the numerical values as specified for the parameters can take negative values. In this case, the exemplary range of values specified with "less than 10" can take negative values, e.g. - 1, - 2, -3, -10, -20, -30, etc.
    1 shows a schematic representation of a system 2 for laser-assisted casting according to various embodiments of the invention. As shown, the system 2 can have a laser system 4, which is programmed to perform a laser ablation on a preliminary wax casting model 6 to form a modified wax model 8, which has at least one cooling hole 10, which is missing in the preliminary wax casting model 6. The preliminary wax casting model 6 may include a raw, unprocessed, or otherwise machine-machined piece of wax material, as described herein. The preliminary wax casting model 6 is produced in a wax casting tool as is known in the art. The system 2 can also have an imaging system 12 for scanning the modified wax model 8 for imaging the at least one cooling hole 10 after the laser ablation has been carried out by the laser system 4. In various embodiments, the imaging system has a rotating scanning system, e.g. an optical trepanning system that is set up to scan features of the at least one cooling hole 10. The imaging system 12, which has an optical trepanning system, can have a resolution with a tolerance of less than about 0.0001 inches (0.00254 centimeters). System 2 may also include a coating system 26 for: a) coating the modified wax model 8 (eg, with a coating metal) to form a mold 22 (or shell) around the modified wax model 8, and b) removing the modified one Wax model 8 to leave a mold 24 (which is also referred to as a cast shell), which has the at least one cooling hole 10. The system 2 may also include a molding system 30 for molding a molding material 32 to form a molded part from the mold 24 (after confirming that the modified wax model 8 has the desired properties and the mold 24 has been created).
    In various embodiments, the system 2 can have a control system 20 which is coupled to the laser system 4, the coating system 26, the casting system 30 and / or the imaging system 12. The control system 20 can be configured to supply instructions to the laser system 4, the coating system 26, the casting system 30 and / or the imaging system 12 and / or to otherwise control their operation. The control system 20 can be mechanically or electrically connected to the laser system 4, the coating system 26, the casting system 30 and / or the imaging system 12. The control system 20 can be a computer-aided, mechanical or electro-mechanical device that is capable of controlling the laser system 4, the coating system 26, the casting system 30 and / or the imaging system 12. In one embodiment, control system 20 may be a computerized device capable of providing operating instructions to laser system 4, coating system 26, casting system 30, and / or imaging system 12. In another embodiment, the control system 20 may include a mechanical device that is capable of being used by an operator. In this case, the operator can physically operate control system 20 (e.g., by pulling a lever), which can activate laser system 4, coating system 26, casting system 30, and / or imaging system 12. In another embodiment, control system 20 may be an electro-mechanical device.
    Referring to FIG. 2 with continued reference to FIG. 1, there is shown a flow diagram that illustrates a method for laser assisted casting that is performed in accordance with various embodiments. As shown, the method can include the following processes:
    Process P1 (optional preliminary process): provision of a preliminary wax casting model 6, e.g. of the preliminary wax casting model 6 (Fig. 1). In various embodiments, the preliminary wax molding model 6 may include hydrocarbon wax, natural ester wax, synthetic wax, natural resins, synthetic resins, organic fillers, water, and mixtures thereof. In certain embodiments, the preliminary wax casting model 6 may have aliphatic compounds (compounds with straight chain carbon atoms, e.g. hydrocarbon wax, natural ester wax, synthetic wax and / or resins) or aromatic compounds compounds, fillers and / or resins with ring-shaped structured carbon atoms).
    Process P2: performing a laser ablation (using the laser system 4) on the preliminary wax casting model 6 to form a modified wax model (eg the modified wax casting model 8) which has at least one cooling hole (eg the cooling hole / cooling holes 10) which missing in the preliminary wax casting model 6. As described herein, the process of performing laser ablation on the preliminary wax cast model 6 may include applying a pulsed laser (eg, an ultra-short pulse laser) on the preliminary wax cast model 6 to directly vaporize a portion 18 of the preliminary wax cast model 6, the at least one cooling hole 10 is trained. The evaporated sections 18 are illustrated by the cooling holes 10 in the modified casting model 8. In various embodiments, the process of direct evaporation comprises raising a local temperature of section 18 of the preliminary wax mold 6 above the evaporation temperature of the preliminary wax mold 6, e.g. about 500 degrees Celsius (and in some cases up to about 1000 degrees Celsius) while maintaining a temperature of the adjacent portion 18 of the preliminary wax mold 6 below its melting temperature, e.g. about 120 degrees Celsius (and in some cases below about 50 degrees Celsius). It is understood that, as described herein, a cooling hole 10 can be created in the preliminary wax casting model 6 by modulating at least one of the following features of the laser system 4: laser pulse duration, power density of the laser pulses, and scanning speed of the laser over the preliminary wax casting model 6 around the cooling hole 10, which has an aspect ratio of approximately one (1) to approximately ten (10). This process can differ from forming an additional feature that has a larger aspect ratio, e.g. greater than about 10. In certain embodiments, the cooling hole 10 has an opening that has an aspect ratio of about 5 to about 10.
    Process P3: Scanning the modified wax casting model 6 (using the imaging system 12, which has an optical trepanning system) to image the at least one cooling hole 10 after performing the laser ablation. In various embodiments, the scanning comprises performing an optical trepanning scan from the at least one cooling hole 10.
    Process P4 (optionally in some embodiments): performing a subsequent laser ablation (using the laser system 4) on the modified casting model 8 on the basis of the image of the at least one cooling hole 10. In various embodiments, the subsequent laser ablation process has a modified laser ablation method, which has a modification of at least one parameter of the laser system 4 compared to the original laser ablation parameter (s), such as: a) laser power; b) laser focus; c) laser scanning speed and / or d) laser pulse duration. The processes P3 and P4 can, as shown in FIG. 1, be repeated on the basis of the results of the imaging and the subsequent laser ablation.
    In various embodiments, additional processes can include:
    Process P5: Coating the modified wax model 8 to form a mold shape (shell) 22. This may include applying a lining material 21 (e.g., a metal) over the modified wax model 8 to form the mold shape (sheath) 22 that represents the outline of the modified wax model 8.
    Process P6: Removing the modified wax model 8 in order to leave a mold 24 (shell) which has the at least one cooling hole 10. This can be a physical removal of the modified wax model 8, e.g. by means of physical or chemical destruction of the modified wax model 8. In some cases, the modified wax model 8 is removed from the mold 24 by breaking, pulling, twisting, etc. of the modified wax model 8 to leave the mold 24 undamaged. In other cases, the modified wax model 8 is heated until it liquefies (or evaporates) and is removed after the heating.
    Process P7: Creating a molded part from a casting material 32 (e.g. a material such as steel or steel alloys) using the casting mold 24, which has the at least one cooling hole 10. The production of the molded part from the casting material 32 using the modified casting mold 24 can comprise: a) casting the casting material 32 into the casting mold 24 with the at least one cooling hole 10; and b) cooling the molding material 32 to solidify the molding. Depending on the particular properties of the casting material 32, the cooling process may include actively cooling the casting material 32 (e.g., by exposing the casting material 32 to a cooling environment) or passively cooling the casting material 32 (e.g., by leaving the casting material 32 to cool to room temperature).
    FIG. 3 shows a schematic process flow diagram illustrating processes for producing a mold 24 according to various embodiments of the invention. As illustrated: a preliminary wax model 8 is subjected to laser ablation, whereby a modified wax model 8 is generated; then a mold 24 is formed around the modified wax model 8; and in some processes, a finished component (e.g., a metal component) is created by pouring a molding material 32 into the mold 24 and then removing that material 32 from the mold 24.
    In various embodiments, components that are described as “connected” to one another can be joined at one or more connection points. In some embodiments, these junctions may include connections between separate components, and in other cases, these junctions may include a fixed and / or integral connection. That is, in some cases, components that are “connected” to each other can be formed simultaneously to define a single continuous element. In other embodiments, however, these components can be formed as separate elements and then joined together by known processes (e.g. fastening, ultrasonic welding, joining).
    Reference list
    [0054]<tb> System <SEP> 2<tb> Laser system <SEP> 4<tb> Wax cast model <SEP> 6<tb> wax model <SEP> 8<tb> cooling hole <SEP> 10<tb> Imaging system <SEP> 12<tb> Section <SEP> 18<tb> Control system <SEP> 20<tb> Lining material <SEP> 21<tb> mold shape <SEP> 22<tb> mold <SEP> 24<tb> coating system <SEP> 26<tb> Casting system <SEP> 30<tb> Casting material <SEP> 32
    权利要求:
    Claims (9)
    [1]
    1. A method for producing a mold, which comprises:Performing a laser ablation on a preliminary wax casting model (6) to form a modified wax model (8) which has at least one cooling hole which is missing in the preliminary wax casting model (6);Coating the modified wax model to form a mold shape (22) around the modified wax model; andRemoving the modified wax model (8) to leave a mold (24) having the at least one cooling hole.
    [2]
    2. The method of claim 1, wherein performing the laser ablation comprises applying an ultra-short pulse laser to the preliminary wax cast model (6) to directly vaporize a portion of the preliminary wax cast model (6), thereby forming the at least one cooling hole, the cooling hole being one Aspect ratio of 5 to 10.
    [3]
    3. The method of claim 2, wherein the direct evaporation comprises raising a local temperature of the portion of the preliminary wax molding model (6) above 500 degrees Celsius.
    [4]
    4. The method of claim 3, wherein the direct evaporation comprises maintaining a temperature of an adjacent portion of the preliminary wax molding model (6) below 120 degrees Celsius.
    [5]
    5. The method according to any one of the preceding claims, further comprising scanning the modified wax model (8) to image the at least one cooling hole after performing the laser ablation and before coating; wherein the scanning preferably comprises performing at least one of a two-dimensional scan and / or a three-dimensional scan of the at least one cooling hole.
    [6]
    6. The method of claim 5, further comprising performing a subsequent laser ablation on the modified wax model (8) based on the image of the at least one cooling hole; wherein the subsequent laser ablation preferably has a modified laser ablation method which, in comparison to the laser ablation, has a modified size of at least one of the following sizes: laser power, laser focus, laser scanning speed or laser pulse duration.
    [7]
    7. The method of claim 1, wherein performing the laser ablation comprises applying a pulsed laser to the preliminary wax cast model to directly vaporize a portion of the preliminary wax cast model, wherein the at least one cooling hole is formed.
    [8]
    8. A method for producing a molded part, which method comprises:Producing a casting mold (24) by means of a method according to one of the preceding claims;Pouring the casting material (32) into the casting mold (24); andCool the casting material (32) to solidify the molded part.
    [9]
    9. System (2) for producing a molded part, which comprises:a laser system (4) programmed to perform laser ablation on a preliminary wax cast model (6) to form a modified wax model (8) having at least one cooling hole missing from the preliminary wax cast model (6);an imaging system (12) having an optical trepanning system for scanning the modified wax model (8) for imaging the at least one cooling hole after performing the laser ablation;a coating system (26) for coating the modified wax model (8) to form a mold shape (22) around the modified wax model (8) and removing the modified wax model (8) to leave a mold (24) that the at least one Has cooling hole; anda casting system (30) for casting a molded part from a casting material (32) using the casting mold (22) which has the at least one cooling hole.
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    同族专利:
    公开号 | 公开日
    CH708863A2|2015-05-15|
    GB201419868D0|2014-12-24|
    GB2520184A|2015-05-13|
    GB2520184B|2018-11-07|
    DE102014116297A1|2015-05-13|
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    法律状态:
    2017-03-15| NV| New agent|Representative=s name: GENERAL ELECTRIC TECHNOLOGY GMBH GLOBAL PATENT, CH |
    2019-05-31| NV| New agent|Representative=s name: FREIGUTPARTNERS IP LAW FIRM DR. ROLF DITTMANN, CH |
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    优先权:
    申请号 | 申请日 | 专利标题
    US14/075,155|US9327344B2|2013-11-08|2013-11-08|Laser assisted casting of cooling hole and related system|
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