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公开(公告)号：US20130032306A1
公开(公告)日：2013-02-07
申请号：US13198506
申请日：2011-08-04
CPC分类号： B22D27/045 , B22D46/00
摘要： A system and method for directionally casting an elongated device are provided. The method includes orienting a mold within a furnace such that a first portion of the mold points downward. The first portion of the mold defines a space within the mold used to form a first end of the device. The first end of the device, when formed, has a greater mass than a second end of the device. The method also includes filling the mold with molten metal and lowering the mold out of the furnace into a liquid metal bath to immerse the first portion of the mold in the liquid metal bath. The method includes concurrently lowering the mold and the liquid metal bath to cool the molten metal.
摘要翻译： 提供了一种用于定向铸造细长装置的系统和方法。 该方法包括将模具定位在炉内，使得模具的第一部分向下指向。 模具的第一部分限定了用于形成装置的第一端的模具内的空间。 器件的第一端形成时具有比器件的第二端更大的质量。 该方法还包括用熔融金属填充模具并将模具从炉中放出到液态金属浴中以将模具的第一部分浸入液态金属浴中。 该方法包括同时降低模具和液态金属浴以冷却熔融金属。
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公开(公告)号：US20090314390A1
公开(公告)日：2009-12-24
申请号：US12145459
申请日：2008-06-24
申请人： Michael Frances Xavier Gigliotti, JR. , Stephen Francis Rutkowski , Shyh-Chin Huang , Roger John Petterson , Luana Emiliana Iorio , Andrew John Elliott
发明人： Michael Frances Xavier Gigliotti, JR. , Stephen Francis Rutkowski , Shyh-Chin Huang , Roger John Petterson , Luana Emiliana Iorio , Andrew John Elliott
CPC分类号： C23C8/10 , B22D19/08 , C23C30/00 , F01D5/28 , F01D5/288 , F05D2230/21 , F05D2230/90 , Y02T50/67
摘要： An alloy casting having a protective layer disposed on a surface of the casting is provided. The protective layer is resistant to liquid metal attack, and wherein the protective layer includes an oxide of an element present in the alloy. A method of forming a protective layer on a surface of the alloy casting is also provided. The method includes disposing the alloy in a mold, and oxidizing an element of the alloy to form a protective layer on the surface of the casting.
摘要翻译： 提供一种具有设置在铸件表面上的保护层的合金铸件。 保护层耐液体金属侵蚀，其中保护层包括存在于合金中的元素的氧化物。 还提供了在合金铸件的表面上形成保护层的方法。 该方法包括将合金设置在模具中，并且氧化合金的元素以在铸件的表面上形成保护层。
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公开(公告)号：US06276433B1
公开(公告)日：2001-08-21
申请号：US09425307
申请日：1999-10-25
IPC分类号： B22D2704
CPC分类号： B22D21/025 , B22D27/045
摘要： A liquid metal cooled directional solidification process provides improved solidification characteristics at the solidification front. In the process, a mold is filled with molten metal; and a solidification interface is caused to pass through the molten metal by progressively immersing the mold into a cooling liquid. The cooling liquid is a eutectic or near eutectic metal composition. A directional solidification furnace includes a heating furnace, a liquid cooling bath and a mold positioner. The heating furnace has an open bottom end through which a heated mold containing molten metal is lowered from the furnace. The liquid cooling bath comprises a molten eutectic or near eutectic metal composition positioned beneath the open end of the furnace. The mold positioner gradually lowers the heated mold from the furnace, through the open end and immerses the mold into the liquid cooling bath.
摘要翻译： 液态金属冷却定向凝固方法在凝固前沿提供了改进的凝固特性。 在该过程中，模具中充满熔融金属; 并且通过将模具逐渐浸入冷却液中，使凝固界面通过熔融金属。 冷却液是共晶或近共晶金属组成。 定向凝固炉包括加热炉，液体冷却槽和模具定位器。 加热炉具有开口的底端，含有熔融金属的加热模具通过该底端从炉中降低。 液体冷却浴包括位于炉的开口端下方的熔融共晶或近共晶金属组合物。 模具定位器通过开口端将炉子的加热模具逐渐降低，并将模具浸入液体冷却浴中。
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4.发明授权Casting molds for use in directional solidification processes and methods of making 有权用于定向凝固过程的铸造模具和制造方法公开(公告)号：US08307881B2
公开(公告)日：2012-11-13
申请号：US12348937
申请日：2009-01-06
申请人： Shyh-Chin Huang , Andrew John Elliott , Michael Francis Xavier Gigliotti, Jr. , Roger John Petterson , Stephen Francis Rutkowski
发明人： Shyh-Chin Huang , Andrew John Elliott , Michael Francis Xavier Gigliotti, Jr. , Roger John Petterson , Stephen Francis Rutkowski
CPC分类号： B22D27/045 , B22C9/04 , C30B11/002
摘要： Casting molds suitable for directional solidification processes using a liquid cooling bath include a graded facecoat structure on a mold body. The graded facecoat structure includes an innermost layer and a delamination layer, wherein the delamination layer fractures upon cooling of the molten metal so as to separate the mold body from the innermost layer, which remains in contact with or in close proximity to the metal being cast. Also disclosed are directional solidification processes.
摘要翻译： 适用于使用液体冷却浴的定向凝固方法的铸模包括在模体上的分级面涂层结构。 分级面涂层结构包括最内层和分层，其中分层在熔融金属冷却时破裂，从而将模具体与最内层分开，其保持与正在铸造的金属接触或非常接近 。 还公开了定向凝固方法。
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5.发明申请Casting Molds for Use in Directional Solidification Processes and Methods of Making 有权用于定向凝固过程的铸造模具和制造方法公开(公告)号：US20100170654A1
公开(公告)日：2010-07-08
申请号：US12348937
申请日：2009-01-06
申请人： Shyh-Chin Huang , Andrew John Elliott , Michael Francis Xavier Gigliotti, JR. , Roger John Petterson , Stephen Francis Rutkowski
发明人： Shyh-Chin Huang , Andrew John Elliott , Michael Francis Xavier Gigliotti, JR. , Roger John Petterson , Stephen Francis Rutkowski
CPC分类号： B22D27/045 , B22C9/04 , C30B11/002
摘要： Casting molds suitable for directional solidification processes using a liquid cooling bath include a graded facecoat structure on a mold body. The graded facecoat structure includes an innermost layer and a delamination layer, wherein the delamination layer fractures upon cooling of the molten metal so as to separate the mold body from the innermost layer, which remains in contact with or in close proximity to the metal being cast. Also disclosed are directional solidification processes.
摘要翻译： 适用于使用液体冷却浴的定向凝固方法的铸模包括在模体上的分级面涂层结构。 分级面涂层结构包括最内层和分层，其中分层在熔融金属冷却时破裂，从而将模具体与最内层分开，其保持与正在铸造的金属接触或非常接近 。 还公开了定向凝固方法。
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公开(公告)号：US08906170B2
公开(公告)日：2014-12-09
申请号：US12145459
申请日：2008-06-24
申请人： Michael Frances Xavier Gigliotti, Jr. , Stephen Francis Rutkowski , Shyh-Chin Huang , Roger John Petterson , Luana Emiliana Iorio , Andrew John Elliott
发明人： Michael Frances Xavier Gigliotti, Jr. , Stephen Francis Rutkowski , Shyh-Chin Huang , Roger John Petterson , Luana Emiliana Iorio , Andrew John Elliott
CPC分类号： C23C8/10 , B22D19/08 , C23C30/00 , F01D5/28 , F01D5/288 , F05D2230/21 , F05D2230/90 , Y02T50/67
摘要： An alloy casting having a protective layer disposed on a surface of the casting is provided. The protective layer is resistant to liquid metal attack, and wherein the protective layer includes an oxide of an element present in the alloy. A method of forming a protective layer on a surface of the alloy casting is also provided. The method includes disposing the alloy in a mold, and oxidizing an element of the alloy to form a protective layer on the surface of the casting.
摘要翻译： 提供一种具有设置在铸件表面上的保护层的合金铸件。 保护层耐液体金属侵蚀，其中保护层包括存在于合金中的元素的氧化物。 还提供了在合金铸件的表面上形成保护层的方法。 该方法包括将合金设置在模具中，并且氧化合金的元素以在铸件的表面上形成保护层。
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公开(公告)号：US08752611B2
公开(公告)日：2014-06-17
申请号：US13198506
申请日：2011-08-04
IPC分类号： B22D27/04
CPC分类号： B22D27/045 , B22D46/00
摘要： A system and method for directionally casting an elongated device are provided. The method includes orienting a mold within a furnace such that a first portion of the mold points downward. The first portion of the mold defines a space within the mold used to form a first end of the device. The first end of the device, when formed, has a greater mass than a second end of the device. The method also includes filling the mold with molten metal and lowering the mold out of the furnace into a liquid metal bath to immerse the first portion of the mold in the liquid metal bath. The method includes concurrently lowering the mold and the liquid metal bath to cool the molten metal.
摘要翻译： 提供了一种用于定向铸造细长装置的系统和方法。 该方法包括将模具定位在炉内，使得模具的第一部分向下指向。 模具的第一部分限定了用于形成装置的第一端的模具内的空间。 器件的第一端形成时具有比器件的第二端更大的质量。 该方法还包括用熔融金属填充模具并将模具从炉中降出到液态金属浴中以将模具的第一部分浸入液态金属浴中。 该方法包括同时降低模具和液态金属浴以冷却熔融金属。
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8.发明申请CASTING METHODS FOR MAKING ARTICLES HAVING A FINE EQUIAXED GRAIN STRUCTURE 审中-公开用于制作具有精细晶粒结构的制品的铸造方法公开(公告)号：US20130160967A1
公开(公告)日：2013-06-27
申请号：US13336470
申请日：2011-12-23
申请人： Akane Suzuki , Stephen Joseph Balsone , Andrew John Elliott , Michael Francis Xavier Gigliotti, JR. , Shyh-Chin Huang , Roger John Petterson , Stephen Francis Rutkowski , Pazhayannur Ramanathan Subramanian
发明人： Akane Suzuki , Stephen Joseph Balsone , Andrew John Elliott , Michael Francis Xavier Gigliotti, JR. , Shyh-Chin Huang , Roger John Petterson , Stephen Francis Rutkowski , Pazhayannur Ramanathan Subramanian
CPC分类号： B22D27/04
摘要： Methods for casting a metallic material to form a component are described. The component can be a superalloy-containing turbine part, for example. The general method includes the step of pouring the metallic material, in molten form, into an investment mold; and then rapidly immersing the entire investment mold into a bath that contains a low-melting liquid coolant metal, so as to achieve substantially uniform, multi-directional heat transfer out of the molten material. The molten material that solidifies to form the component is characterized by a fine-grained, equiaxed grain structure. Related embodiments include the use of two ingots that constitute the superalloy material. One ingot includes the oxygen-reactive elements, and is prepared by a vacuum-melting technique. The other ingot includes the remainder of the elements, and can be prepared by a number of techniques, such as air-melting processes.
摘要翻译： 描述用于铸造金属材料以形成部件的方法。 该组件例如可以是含有超合金的涡轮机部件。 通常的方法包括以熔融形式将金属材料倒入投资模具中的步骤; 然后将整个投资模具快速浸入含有低熔点液体冷却剂金属的浴中，从而实现从熔融材料中的大致均匀的多方向热传递。 凝固形成组分的熔融材料的特征在于细晶粒等轴晶粒结构。 相关实施例包括使用构成超级合金材料的两个锭。 一个锭包括氧反应元素，并通过真空熔融技术制备。 另一个锭包括剩余的元素，并且可以通过许多技术制备，例如空气熔化过程。
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9.发明授权公开(公告)号：US08210240B2
公开(公告)日：2012-07-03
申请号：US12474475
申请日：2009-05-29
申请人： Shyh-Chin Huang , Stephen Francis Rutkowski , Michael Francis Xavier Gigliotti, Jr. , Roger John Petterson , Lawrence Bernard Kool
发明人： Shyh-Chin Huang , Stephen Francis Rutkowski , Michael Francis Xavier Gigliotti, Jr. , Roger John Petterson , Lawrence Bernard Kool
CPC分类号： B22D27/045
摘要： A casting process and apparatus for producing directionally-solidified castings, and castings produced therewith. The process entails applying a facecoat slurry to a surface within a mold cavity to form a continuous solid facecoat on the surface, introducing a molten metal alloy into the mold cavity so that the molten metal alloy contacts the facecoat, and then immersing the mold in a liquid coolant to cool and solidify the molten metal alloy and form a casting of the metal alloy, during which an oxide layer forms on the casting surface. The facecoat is sufficiently adherent to the oxide layer such that at least a portion of the facecoat detaches from the mold surface and remains tightly adhered to the casting surface in the event the casting contracts during cooling. The facecoat contains at least 60 weight percent of a first phase of yttria, and the balance of the facecoat is a binder phase of an inorganic material.
摘要翻译： 用于生产定向凝固铸件的铸造工艺和设备，以及由其制造的铸件。 该方法需要将表面涂层浆料施加到模腔内的表面以在表面上形成连续的实心面涂层，将熔融金属合金引入模腔中，使得熔融金属合金接触面涂层，然后将模具浸入 液体冷却剂以冷却和固化熔融金属合金，并形成金属合金的铸件，在此期间在铸造表面上形成氧化物层。 表面涂层与氧化物层充分贴合，使得至少一部分正面涂层在模具表面脱离并在冷却期间铸件收缩的情况下保持紧密地粘附于铸造表面。 面涂层含有至少60重量％的第一相的氧化钇，其余的表面涂层是无机材料的粘结相。
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公开(公告)号：US20110315338A1
公开(公告)日：2011-12-29
申请号：US13226816
申请日：2011-09-07
申请人： Michael Francis Xavier Gigliotti , Shyh-Chin Huang , Adegboyega Masud Makinde , Roger John Petterson , Stephen Francis Rutkowski , Venkat Subramaniam Venkataramani
发明人： Michael Francis Xavier Gigliotti , Shyh-Chin Huang , Adegboyega Masud Makinde , Roger John Petterson , Stephen Francis Rutkowski , Venkat Subramaniam Venkataramani
CPC分类号： B22C9/04
摘要： Shell molds and processes for making the shell molds that exhibit high emissivity in the red and infrared regions. In this manner, thermal resistance within a gap formed between solidifying cast metal and the interior mold surface is decreased. In one embodiment, the facecoat region is formed from a slurry composition comprising an aluminum oxide, a green chromium oxide and a silicon dioxide. In another embodiment, the facecoat region is formed from a slurry composition including zirconium silicate and silica with stucco layer of alumina is included.
摘要翻译： 壳模具和用于制造在红色和红外区域表现出高发射率的壳模具的工艺。 以这种方式，在凝固铸造金属和内部模具表面之间形成的间隙内的热阻降低。 在一个实施方案中，面涂层区域由包含氧化铝，绿色氧化铬和二氧化硅的浆料组合物形成。 在另一个实施方案中，面涂层区域由包括硅酸锆和二氧化硅的淤浆组合物形成，其中包括氧化铝灰泥层。
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