公开(公告)号：US20170320132A1

公开(公告)日：2017-11-09

申请号：US15477769

申请日：2017-04-03

Applicant: ROLLS-ROYCE PLC

Inventor： Martin R. PERRY ,  Kevin GOODWIN ,  Neil DSOUZA

IPC: B22D27/04 ,  B22D27/20 ,  B22C9/22 ,  B22C9/08 ,  B22C9/00

CPC classification number: B22D27/045 ,  B22C9/00 ,  B22C9/04 ,  B22C9/082 ,  B22C9/22 ,  B22D27/20 ,  C30B11/002 ,  C30B29/52 ,  F05D2230/21

Abstract: A mould for casting a component in a directional solidification casting process having a preferred direction of grain growth (non-axial ) comprises a shell defining a cavity for receiving molten material. The cavity defines a three dimensional shape made up of a finished component geometry portion (42, 43, 44) and a sacrificial geometry portion (45) wherein the sacrificial geometry portion (45) includes a notch (48) which is shaped and positioned so as to, in use, contain high angle grain boundaries between dendritic growth in the preferred direction (non-axial ) and dendritic growth in a competing direction to the preferred direction (axial ) within the sacrificial geometry portion of a casting solidifying in the mould.

公开(公告)号：US20170216912A1

公开(公告)日：2017-08-03

申请号：US15399438

申请日：2017-01-05

Applicant: ROLLS-ROYCE plc

Inventor： Paul A. TENNANT ,  Kevin GOODWIN

IPC: B22D27/04 ,  B22D41/00 ,  B22D15/04 ,  F01D11/00 ,  F04D29/54 ,  F04D29/08 ,  F01D5/12 ,  F01D9/02 ,  B22D25/02 ,  F04D29/32

Abstract: An apparatus for the simultaneous casting of multiple components using a directional solidification process includes; a pouring cup arranged on a centreline, an array of moulds encircling the pouring cup and centre line, an array of feed channels extending from the pouring cup to a top end of each mould, and a heat deflector. The heat deflector comprises a wall arranged between the array of moulds and the centreline extending along the length of the moulds and in thermal contact with the moulds.

公开(公告)号：US20240399445A1

公开(公告)日：2024-12-05

申请号：US18667726

申请日：2024-05-17

Applicant: ROLLS-ROYCE PLC

Inventor： Neil D'SOUZA ,  Kevin GOODWIN ,  John D LEHANE ,  Martin R PERRY

IPC: B22C9/04 ,  B22C7/02 ,  B22D25/06 ,  B22D27/20

Abstract: A method of manufacturing a component includes forming a mould assembly including an initial mould unit, providing a seed crystal including a primary growth direction, determining an optimal angular orientation of the unit, rotating the unit to dispose the unit's optimal angular orientation, encasing the unit in a refractory material, and forming a refractory mould unit having a component mould including a mould wall defining a mould cavity, and a seed holder. In the optimal angular orientation, the seed crystal's primary growth direction is angled away from the wall, thereby forming a converging disposition with the wall in a of the wall's first region facing the central sprue and a diverging disposition with the wall in the wall's second region facing a mould heater. The method includes receiving the seed crystal within the seed holder and filling the mould cavity with molten castable material to form the component.

公开(公告)号：US20150225828A1

公开(公告)日：2015-08-13

申请号：US14614732

申请日：2015-02-05

Applicant: ROLLS-ROYCE PLC

Inventor： Neil John D'SOUZA ,  Kevin GOODWIN ,  Martin Richard PERRY

IPC: C22F1/10 ,  C22C19/05 ,  C22F1/00 ,  C22F1/02 ,  C23C8/10 ,  C23C8/80

CPC classification number: C22F1/10 ,  C22C19/057 ,  C22F1/002 ,  C22F1/008 ,  C22F1/02 ,  C23C8/10 ,  C23C8/80

Abstract: Producing a Ni superalloy component in which the superalloy has a γ phase matrix containing intermetallic γ′ precipitates. Providing a Ni superalloy casting of the component; solutioning the component by heat treating the casting under vacuum and/or in an inert atmosphere at a temperature above the γ′ solvus to homogenise the γ phase; quenching and ageing the solutioned component to grow intermetallic γ′ precipitates in the homogenised γ phase. Before the solutioning step: heat treating the casting to produce a thermally grown oxide on the surface, oxide adherent to supress volatilisation of Ni from the surface of the casting during the solutioning heat treatment. Performing the solutioning step under a Ni vapour pressure which is sufficient to supress volatilisation of Ni from the surface of the casting during the solutioning heat treatment. During the solutioning heat treatment the component is encapsulated in a container protecting the casting from Si-doped contaminants.

Abstract translation: 生产Ni超合金组分，其中超合金具有含有金属间γ'析出物的γ相基体。 提供组件的Ni超合金铸件; 通过在真空和/或在惰性气氛中在高于γ'solvus的温度下热处理铸件来使组分溶解以均化γ相; 淬火和老化溶液中的组分以在匀质γ相中生长金属间γ'析出物。 在解决步骤之前：对铸件进行热处理以在表面上产生热生长的氧化物，氧化物粘附以在溶液热处理期间从铸件的表面抑制Ni的挥发。 在Ni蒸汽压力下进行溶解步骤，其足以抵抗在溶液热处理期间来自铸件表面的Ni的挥发。 在固溶热处理期间，将组分封装在保护铸件免受Si掺杂污染物的容器中。