Arcuate seed casting method

Patent metadata

Field	Value
Publication number	US-12005493-B2
Application number	US-202217829786-A
Country	US
Kind code	B2
Filing date	Jun 1, 2022
Priority date	Oct 4, 2019
Publication date	Jun 11, 2024
Grant date	Jun 11, 2024

Abstract

A casting method includes forming a seed. The seed has a first end and a second end and an inner diameter (ID) surface and an outer diameter (OD) surface. The seed second end is placed in contact or spaced facing relation with a chill plate. The first end is contacted with molten material. The molten material is cooled and solidified so that a crystalline structure of the seed propagates into the solidifying material. At least a portion of the seed contacted with the molten material has a solidus higher than a solidus of at least an initial pour portion of the molten material.

First claim

What is claimed is:

1. A casting method comprising:
forming a seed, the seed having a first end and a second end and an inner diameter (ID) surface and an outer diameter (OD) surface;
placing the seed second end in contact or spaced facing relation with a chill plate;
contacting the first end with molten material; and
cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material,

wherein:
the forming of the seed includes applying a melting point depressant to a seed precursor along at least a portion of the seed contacted with the molten material.

2. The method of claim 1 wherein:
the melting point depressant comprises boron; and
the melting point depressant produces a remelt temperature lower than a recrystallization temperature.

3. The method of claim 1 wherein:
the melting point depressant is applied by vapor deposition.

4. The method of claim 1 wherein:
the melting point depressant is applied by slurry coating.

5. The method of claim 4 wherein:
the slurry comprises a powder mixture of alloys of at least two different compositions.

6. The method of claim 5 wherein:
the at least two different compositions comprise two compositions differing in boron content.

7. The method of claim 4 wherein:
the slurry comprises a boron-containing alloy powder.

8. The method of claim 1 wherein:
the melting point depressant comprises a powder mixture of alloys of at least two different compositions.

9. The method of claim 8 wherein:
the molten material solidifies as a full annulus component.

10. The method of claim 1 wherein:
the melting point depressant is applied on a top surface of the seed precursor.

11. The method of claim 1 wherein:
the melting point depressant is effective to increase a height of melt back along at least one of the inner diameter surface and the outer diameter surface.

12. The method of claim 1 wherein:
the seed precursor has a solidus no more than 25° C. higher, if at all, than a solidus of the molten material.

13. The method of claim 1 wherein:
the seed precursor and the molten material are essentially identical compositions.

14. The method of claim 1 wherein:
the molten material solidifies as a full annulus component.

15. The method of claim 1 wherein:
the melting point depressant is applied by vapor deposition.

16. The method of claim 15 wherein:
the melting point depressant is a nickel alloy.

17. The method of claim 16 wherein:
the melting point depressant is applied to a thickness of 5.0 micrometers to 50 micrometers.

18. The method of claim 17 wherein:
the molten material solidifies as a full annulus component.

19. The method of claim 15 wherein:
the molten material solidifies as a full annulus component.

20. The method of claim 1 wherein:
the melting point depressant is effective to increase a height of melt back along the inner diameter surface and the outer diameter surface.

Assignees

• Raytheon Tech Corp
• Rtx Corp

Inventors

• Shah Dilip M
• Bullied Steven J
• Breneman Ryan C
• Woodard Shiela R
• Verner Carl R

Classifications

• B22D27/045 Primary

  Directionally solidified castings · CPC title

• C30B29/52

  Alloys · CPC title

• C30B11/14

  characterised by the seed, e.g. its crystallographic orientation · CPC title

• B22D27/04 Primary

  Influencing the temperature of the metal, e.g. by heating or cooling the mould · CPC title

• F05D2300/605

  Crystalline · CPC title