Refining and casting apparatus and method

Abstract

An apparatus for casting metals by a nucleated casting technique to create a preform, the apparatus including a mold having a base and a side wall where the base can be moved relative to the side wall to withdraw the preform as it is being created. In various circumstances, portions of a droplet spray created by an atomizing nozzle, i.e., overspray, may accumulate on a top surface of the side wall and prevent or inhibit the preform from being moved relative to the side wall. The atomizing nozzle can be oriented such that the droplet spray passes over the top of the side wall to remelt and remove at least a portion of the overspray that has accumulated thereon. The mold can be rotated such that the overspray formed on a region of or on the entire perimeter of the top surface can pass through the droplet spray and can be removed from the side wall.

Claims

1. An apparatus for producing a preform by nucleated casting, the apparatus comprising: an atomizing nozzle is structured to produce a droplet spray of molten metallic material for producing the preform; a mold in which the preform is formed, wherein said mold comprises: a base, a side wall, and an axis of rotation, wherein said base rotates about said axis of rotation, and wherein said side wall includes a top surface and is adapted to selectively rotate completely about said axis of rotation, wherein said base is movable relative to said side wall along said axis of rotation to control a distance between said atomizing nozzle and said base; and wherein said atomizing nozzle is configured to produce said droplet spray in a direction that is neither parallel to nor collinear with said axis of rotation, and wherein at least a portion of said droplet spray is directed into the mold and passes over said top surface to remelt at least a portion of metallic material accumulated on said top surface.

2. The apparatus of claim 1, wherein impact of the droplet spray produced by said atomizing nozzle into said mold generates a turbulent zone of metallic material within the mold.

3. The apparatus of claim 1, wherein said apparatus further comprises an atomizing gas supply in communication with said atomizing nozzle to create the droplet spray of the molten metallic material.

4. The apparatus of claim 1, wherein said atomizing nozzle at least one of: selectively oscillates with respect to said mold; and selectively rasters with respect to said mold.

5. The apparatus of claim 1, further comprising a stalk connected to said base, wherein said stalk moves said base with respect to said side wall along said axis of rotation, wherein said stalk includes a slot, and wherein said apparatus further comprises a guide rail positioned within said slot to rotate said side wall and to guide said stalk as it is moves said base along said axis of rotation.

6. The apparatus of claim 1, wherein said side wall includes a recess, and wherein said apparatus further comprises a guide rail positioned within said recess to rotate said side wall about said axis of rotation.

7. The apparatus of claim 1, wherein said mold further includes a bearing surface extending from said side wall, and wherein said apparatus further includes a bracket rotatably supporting said bearing surface.

8. A method of casting a metallic material, the method comprising: melting a metallic material to provide a molten material; forming a droplet spray of the molten material along a spray axis from an atomizing nozzle by impinging a gas on a flow of the molten material; and depositing the droplet spray of the molten material within a mold comprising: a base; a side wall; and an axis of rotation, wherein the side wall is adapted to rotate completely about the axis of rotation, wherein the base is retractable relative to the atomizing nozzle along the axis of rotation to control a distance between the atomizing nozzle and the base, and wherein the spray axis is oriented at an angle with respect to said axis of rotation.

9. The method of claim 8, wherein depositing the droplet spray comprises generating a turbulent zone of the metallic material within the mold by impact of the droplet spray.

10. The method of claim 8, wherein depositing the droplet spray comprises depositing the droplet spray of the molten material within the mold under at least one of a partial vacuum and a protective gas atmosphere.

11. The method of claim 8, wherein depositing the droplet spray of the molten material within the mold comprises passing the droplet spray over a top surface of the side wall to remove metallic material that has accumulated on the top surface.

12. The method of claim 8, wherein the base is adapted to rotate about the axis of rotation.

13. The method of claim 8, wherein rotation of the base can be coupled with rotation of the side wall.

14. A method of casting a metallic material, the method comprising: melting a metallic material to provide a molten material; forming a droplet spray of the molten material with an atomizing nozzle by impinging a gas on a flow of the molten material; depositing the droplet spray of the molten material within a mold, the mold having a top surface; and impinging at least a portion of the droplet spray on the top surface of the mold as the droplet spray is deposited into the mold to remove metallic material that has accumulated on the top surface.

15. The method of claim 14, wherein the mold further includes a side wall, wherein the side wall includes the top surface of the mold, and wherein said method further comprises rotating the side wall relative to the droplet spray about an axis of rotation.

16. The method of claim 15, wherein forming the droplet spray includes directing the droplet spray toward the axis of rotation.

17. The method of claim 14, wherein the mold further includes a side wall and a base, and wherein said method further comprises moving the base relative to the side wall along a withdrawal axis.

18. The method of claim 17, wherein forming the droplet spray includes directing the droplet spray in a direction which is neither parallel to nor collinear with the withdrawal axis.

19. A method of casting a metallic material, the method comprising: melting a metallic material to provide a molten material; forming a droplet spray of the molten material with an atomizing nozzle by impinging a gas on a flow of the molten material; depositing at east a portion of the droplet spray of the molten material within a mold, the mold comprising a side wall including a top surface; and impinging at least a portion of the droplet spray on metallic material accumulated on the top surface of the side wall to remove at least a portion of metallic material accumulated on the top surface.

20. The method of claim 19, wherein depositing at least a portion of the droplet spray comprises generating a turbulent zone of the molten material within the mold by impact of the droplet spray.

21. The method of claim 19, wherein depositing the droplet spray comprises depositing the droplet spray of the molten material within the mold under at least one of a partial vacuum and a protective gas atmosphere.

22. The method of claim 19, further comprises rotating the side wall relative to the droplet spray about an axis of rotation.

23. The method of claim 22, wherein forming the droplet spray includes directing the droplet spray in a direction which is neither parallel to nor collinear with the axis of rotation.

24. The method of claim 22, wherein the mold further includes a base, and wherein said method further comprises moving the base relative to the side wall along a withdrawal axis.

25. The method of claim 24, wherein the base is adapted to rotate about the axis of rotation.

26. The method of claim 25, wherein rotation of the base can be coupled with rotation of the side wall.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The features and advantages of the present invention may be better understood by reference to the accompanying drawings in which:

(2) FIG. 1 is a block diagram of an embodiment of the refining and casting method according to the present invention;

(3) FIG. 2 is a schematic representation of an embodiment of a refining and casting apparatus constructed according to the present invention;

(4) FIGS. 3A and 3B are graphs illustrating parameters calculated for a simulated casting of a melt of alloy 718 using a refining and casting apparatus constructed as shown schematically in FIG. 2, and operated with a mass flow rate of 8.5 lbs/minute;

(5) FIGS. 4A and 4B are graphs illustrating parameters calculated for a simulated casting of a melt of alloy 718 using a refining and casting apparatus constructed as shown schematically in FIG. 2, and operated with a mass flow rate of 25.5 lbs/minute;

(6) FIG. 5 depicts the embodiment of the apparatus of the invention used in the trial castings of Example 2;

(7) FIG. 6 is an as-sprayed center longitudinal micrograph (approximately 50 magnification) of an ingot cast using an apparatus constructed according to the present invention, and demonstrating an equiaxed ASTM 4.5 grain structure;

(8) FIG. 7 is an as-cast micrograph taken from a 20-inch diameter VAR ingot (approximately 50 magnification);

(9) FIG. 8 is a schematic representation of one non-limiting embodiment of a nucleated casting apparatus constructed according to the present invention; and

(10) FIG. 9 is a second schematic representation of the nucleated casting apparatus of FIG. 8.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

(11) In one aspect, the present invention provides a novel process for refining a metallic material and casting the material to a preform. The preform may be processed to provide a finished article. The process of the invention includes melting and refining the metallic material and subsequently casting the material to a preform by a nucleated casting technique. Melting and refining the material may be accomplished by, for example, electroslag remelting (ESR) or vacuum arc remelting (VAR). The process of the invention also includes transferring the molten refined material to a nucleated casting apparatus through a passage so as to protect it from contamination. The passage may be that formed through a cold induction guide (CIG) or another transfer apparatus.

(12) The present invention also provides an apparatus combining at least an apparatus for melting and refining the metallic material, an apparatus for producing the preform from the molten refined material by nucleated casting, and a transfer apparatus for transferring the molten refined material from the melting and refining apparatus to the nucleated casting apparatus. As further described below, the apparatus and method of the invention are particularly advantageous when applied in the production of large diameter, high purity preforms from metallic materials prone to segregation during casting. For example, large diameter (12-14 inches or more) preforms may be produced from segregation prone and other difficult to cast metallic materials by the present apparatus and method which are substantially free from melt-related defects and exhibit minimal segregation.

(13) One embodiment of the apparatus and method of the present invention is depicted in FIG. 1. In a first step, a consumable electrode of a metallic material is subjected to ESR, in which a refined heat of the material is generated by passage of electric current through the electrode and an electrically conductive slag disposed within a refining vessel and in contact with the electrode. The droplets melted from the electrode pass through and are refined by the conductive slag, are collected by the refining vessel, and may then be passed to a downstream apparatus. The basic components of an ESR apparatus typically include a power supply, an electrode feed mechanism, a water cooled copper refining vessel, and the slag. The specific slag type used will depend on the particular material being refined. The ESR process is well known and widely used, and the operating parameters that will be necessary for any particular electrode type and size may readily be ascertained by one having ordinary skill in the art. Accordingly, further detailed discussion of the manner of construction or mode of operation of an ESR apparatus or the particular operating parameters used for a particular material and/or electrode type and size is unnecessary. As indicated in FIG. 1, an alternative embodiment of the apparatus and method of the present invention includes a vacuum arc remelting (VAR) apparatus to melt and refine the metallic material.

(14) As further indicated in FIG. 1, the embodiment also includes a CIG in fluid communication, either directly or indirectly, with the ESR apparatus. The CIG is used to transfer the refined melt produced in the ESR to a nucleated casting apparatus. The CIG maintains the molten refined material produced by ESR in a molten form during transfer to the nucleated casting apparatus. The CIG also maintains the purity of the melt achieved through ESR by protecting the molten material from the atmosphere and from the recontamination that can result from the use of a conventional nozzle. The CIG preferably is directly coupled to both the ESR apparatus and the nucleated casting apparatus so as to better protect the refined molten material from the atmosphere, preventing oxides from forming in and contaminating the melt. Properly constructed, the CIG also may be used to meter the flow of the molten refined material from the ESR apparatus to the nucleated casting apparatus. The construction and manner of use of a CIG, also variously referred to as a cold finger or cold wall induction guide, is well known in the art and is described in, for example, U.S. Pat. Nos. 5,272,718, 5,310,165, 5,348,566, and 5,769,151, the entire disclosures of which are hereby incorporated herein by reference. A CIG generally includes a melt container for receiving molten material. The melt container includes a bottom wall in which is formed an aperture. A transfer region of the CIG is configured to include a passage, which may be generally funnel-shaped, constructed to receive molten material from the aperture in the melt container. In one conventional construction of a CIG, the wall of the funnel-shaped passage is defined by a number of fluid-cooled metallic segments, and the fluid-cooled segments define an inner contour of the passage that generally decreases in cross-sectional area from an inlet end to an outlet end of the region. One or more electrically conductive coils are associated with the wall of the funnel-shaped passage, and a source of electrical current is in selective electrical connection with the conductive coils.

(15) During the time that the molten refined material is flowing from the melt container of the CIG through the passage of the CIG, electrical current is passed through the conductive coils at an intensity sufficient to inductively heat the molten material and maintain it in molten form. A portion of the molten material contacts the cooled wall of the funnel-shaped passage of the CIG and may solidify to form a skull that insulates the remainder of the melt flowing through the CIG from contacting the wall. The cooling of the wall and the formation of the skull assures that the melt is not contaminated by the metals or other constituents from which the inner walls of the CIG are formed. As is known in the art, the thickness of the skull at a region of the funnel-shaped portion of the CIG may be controlled by appropriately adjusting the temperature of the coolant, the flow rate of the coolant, and/or the intensity of the current in the induction coils to control or entirely shut off the flow of the melt though the CIG; as the thickness of the skull increases, the flow through the transfer region is correspondingly reduced. With regard to that feature, reference is made to, for example, U.S. Pat. No. 5,649,992, the entire disclosure of which is hereby incorporated herein by reference.

(16) CIG apparatuses may be provided in various forms, but each such CIG typically includes the following: (1) a passage is provided utilizing gravity to guide a melt; (2) at least a region of the wall of the passage is cooled so as to allow formation of a skull of the melt on the wall; and (3) electrically conductive coils are associated with at least a portion of the passage, allowing inductive heating of molten material passing through the passage. Persons having ordinary skill in the art may readily provide an appropriately designed CIG having any one or all of the forgoing three features for use in an apparatus constructed according to the present invention without further discussion herein.

(17) The CIG is in direct or indirect fluid communication with the nucleated casting apparatus and transfers the refined molten material from the ESR apparatus to the casting apparatus. Nucleated casting is known in the art and is described in, for example, U.S. Pat. No. 5,381,847 and in D. E. Tyler and W. G. Watson, Proceedings of the Second International Spray Forming Conference (Olin Metals Research Labs., September 1996), each of which is hereby incorporated herein by reference. In nucleated casting, a liquid stream of metallic material is disrupted or broken into a cone of sprayed droplets by an impinging gas flow. The resultant cone of droplets is directed into a casting mold having bottom and side walls, where the droplets accumulate to provide a preform having a shape that conforms to the mold. The gas flow rate used to generate the droplets in the nucleated casting process is adjusted to provide a relatively low fraction of solid (relative to the spray forming process) within the individual droplets. This produces a low viscosity material that is deposited in the mold. The low viscosity semi-solid material fills and may conform to the contour of the mold. The impinging gas and impacting droplets create turbulence at the semi-solid surface of the casting as it is deposited, enhancing the uniform deposition of the casting within the mold. By depositing a semi-solid material into the mold with a gas flowing over the surface of the material as it is deposited, the solidification rate of the material is enhanced and a fine grain structure results.

(18) As incorporated in the present invention in conjunction with the melting/refining apparatus and the transfer apparatus, the nucleated casting apparatus may be used to form relatively large cast preforms, preforms of 16 inches or more in diameter. Consumable feed electrodes cast through the apparatus of the invention may be of a size adequate to provide a continuous stream of molten material exiting from the outlet of the transfer apparatus over a prolonged period to deliver a large volume of molten material to the nucleated casting apparatus. Preforms that may be successfully cast by the nucleated casting process include alloys that otherwise are prone to segregation such as, for example, complex nickel-based superalloys, including alloy 706, alloy 718, alloy 720, Rene'88, titanium alloys (including, for example Ti(6-4) and Ti(17)), certain steels, and certain cobalt-base alloys. Other metallic materials that are prone to segregation upon casting will be readily apparent to those of ordinary skill. Preforms of such metallic materials may be formed to large diameters by nucleated casting without casting-related defects such as white spots, freckles, beta flecks, and center segregation. Of course, the apparatus of the invention also may be applied to cast preforms of metallic materials that are not prone to segregation.

(19) As is the case with ESR and CIG, nucleated casting is well known in the art and one of ordinary skill may, without undue experimentation, after having considered the present description of the invention, construct a nucleated casting apparatus or adapt an existing apparatus to receive a melt from a transfer apparatus as in the present invention. Although nucleated casting and spray forming both use a gas to atomize a molten stream to form a plurality of molten alloy droplets, the two processes differ in fundamental respects. For example, the gas-to-metal mass ratios (which may be measured as kilograms of gas/kilograms of metal) used in each process differ. In the nucleated casting process incorporated in the present invention, the gas-to-metal mass ratio and the flight distance are selected so that before impacting the collection surface of the mold or the surface of the casting being formed up to about 30 volume percent of each of the droplets is solidified. In contrast, the droplets impacting the collection surface in a typical spray forming process, such as that described in, for example, U.S. Pat. No. 5,310,165 and European application no. 0 225 732, include about 40 to 70 volume percent of solid. To ensure that 40 to 70 percent of the spray droplets are solid, the gas-to-metal mass ratio used to create the droplet spray in spray forming typically is one or greater. The lower solids fractions used in nucleated casting are selected to ensure that the deposited droplets will conform to the casting mold and voids will not be retained within the casting. The 40-70 volume percent solids fraction used in the spray forming process is selected to form a free-standing preform and would not be suitable for the nucleated casting process.

(20) An additional distinction of spray forming is that although both spray forming and nucleated casting collect the atomized droplets into a solid preform, in spray forming the preform is deposited on a rotating collector that lacks side walls to which the deposited material conforms. Significant disadvantages associated with that manner of collection include porosity in the preform resulting from gas entrapment and significant yield losses resulting from overspray. Although porosity may be reduced in spray formed ingots during hot working, the porosity may reappear during subsequent high temperature heat treatment. One example of that phenomenon is porosity resulting from argon entrapment in superalloys, which can appear during thermally induced porosity (TIP) testing and may act as nucleating sites for low cycle fatigue fractures.

(21) Spray forming also has limited utility when forming large diameter preforms. In such cases a semi-liquid layer must be maintained on the sprayed surface at all times to obtain a satisfactory casting. This requires that any given segment of a surface being spray formed must not solidify between the time that it exits the spray cone, rotates with the collector about the rotational axis of the collector, and reenters the spray cone. That restriction (in combination with the limitation on rotational speed imposed by the centrifugal forces) has limited the diameter of preforms that may be spray formed. For example, spray forming devices with a single spray nozzle may only form preforms having a diameter no larger than about 12 inches. In the present invention, the inventors have found that the use of nucleated casting greatly increases the size of castings that may be formed from molten metallic materials prepared by the melting and refining apparatus/transfer apparatus combination. Because, relative to spray forming, the nucleated casting process may be configured to evenly distribute the droplets supplied to the mold and solidification may ensue rapidly thereafter, any residual oxides and carbonitrides in the preform will be small and finely dispersed in the preform microstructure. An even distribution of droplets may be achieved in the nucleated casting process by, for example, rastering the one or more droplet spray nozzles and/or translating and/or rotating the mold relative to the droplet spray in an appropriate pattern.

(22) A schematic representation of a refining and casting apparatus 10 constructed according to the present invention is shown in FIG. 2. The apparatus 10 includes a melting and refining apparatus in the form of an ESR apparatus 20, a transfer apparatus in the form of CIG 40, and a nucleated casting apparatus 60. The ESR apparatus 20 includes an electric power supply 22 which is in electrical contact with a consumable electrode 24 of the metallic material to be cast. The electrode 24 is in contact with a slag 28 disposed in an open bottom, water-cooled vessel 26 that may be constructed of, for example, copper or another suitable material. The electric power supply 22 provides a high amperage, low voltage current to a circuit that includes the electrode 24, the slag 28, and the vessel 26. The power supply 22 may be an alternating or direct current power supply. As current passes through the circuit, electrical resistance heating of the slag 28 increases its temperature to a level sufficient to melt the end of the electrode 24 in contact with the slag 28. As the electrode 24 begins to melt, droplets of molten material form, and an electrode feed mechanism (not shown) is used to advance the electrode 24 into the slag 28 as the electrode melts. The molten material droplets pass through the heated slag 28, and the slag 28 removes oxide inclusions and other impurities from the material. After passing through the slag 28, the refined molten material 30 pools in the lower end of the vessel 26. The pool of refined molten material 30 then passes to a passage 41 within the CIG 40 by force of gravity.

(23) The CIG 40 is closely associated with the ESR apparatus 20 and, for example, an upper end of the CIG 40 may be directly connected to the lower end of the ESR apparatus 20. In the apparatus 10, the vessel 26 forms both a lower end of the ESR apparatus 20 and an upper end of the CIG 40. Thus, it is contemplated that the melting and refining apparatus, transfer apparatus, and nucleated casting apparatus of the refining and casting apparatus of the invention may share one or more elements in common. The CIG 40 includes a funnel-shaped transfer portion 44 surrounded by current carrying coils 42. Electrical current is provided to the coils 42 by an alternating current source (not shown). The coils 42 serve as induction heating coils and are used to selectively heat the refined molten material 30 passing through the transfer portion 44. The coils 42 are cooled by circulating a suitable coolant such as water through conduits associated with the transfer portion 44. The cooling effect of the coolant also causes a skull (not shown) of solidified material to form on the inner wall of the transfer portion 44. Control of the heating and/or cooling of the transfer portion 44 may be used to control the rate of, or to interrupt entirely, the flow of molten material 30 through the CIG 40. Preferably, the CIG 40 is closely associated with the ESR apparatus 20 so that the molten refined material exiting the ESR apparatus 20 is protected from the atmosphere and does not, for example, undergo oxidation.

(24) Molten material exits a bottom orifice 46 of the CIG 40 and enters the nucleated casting apparatus 60. In the nucleated casting apparatus 60, a supply of suitably inert atomizing gas 61 is delivered to an atomizing nozzle 62. The flow of gas 61 exiting the atomizing nozzle 62 impinges the stream of molten material 30 and breaks the stream into droplets 64. The resulting cone of droplets 64 is directed into a casting mold 65 including a side wall 66 and a base 67. As the material is deposited into the casting mold 65, the base 67 may rotate to better ensure uniform deposition of the droplets. The droplets 64 produced by the apparatus 10 are larger than those of conventional spray casting. The larger droplets 64 are an advantage over conventional spray casting in that they exhibit reduced oxygen content and require less gas consumption for atomization. Also, the gas-to-metal ratio of the droplets produced by the nucleated casting apparatus 60 may be less than one-half that conventionally used in spray forming. The flow rate of gas 61 and the flight distance of the droplets 64 are adjusted to provide a semi-solid material of a desired solid to liquid ratio in the casting mold 65. The desired solid to liquid ratio is in the 5%-40% range, volume per volume. The relatively low solids fraction of the droplets directed into the casting mold 65 results in the deposit of a low viscosity semi-solid material 68 that conforms to the shape of the casting mold 65 as it is filled.

(25) The impact of the spray of droplets 64 creates a turbulent zone at the uppermost surface 70 of the preform 72. The depth of the turbulent zone is dependent upon the velocity of the atomization gas 61 and the size and velocity of the droplets 64. As the droplets 64 begin to solidify, small particles of solid form in the liquid having the lattice structure characteristic of the given material. The small particle of solid which begins to form in each of the droplets then acts as a nucleus onto which other atoms in the vicinity tend to attach themselves. During solidification of the droplets 64, many nuclei form independently at various locations and have random orientation. The repetitive attachment of succeeding atoms results in the growth of crystals composed of the same basic patterns that extend outward from the respective nuclei until the crystals begin to intersect with one another. In the present invention, sufficient nuclei are present as fine dendritic structures within each of the droplets 64 so that the resulting preform 72 formed will consists of a uniform equiaxed grain structure.

(26) To maintain the desired solids fraction in the material deposited in the casting mold 66, the distance between the point of atomization and the upper surface 70 of the preform 72 is controlled. Thus, the apparatus 10 of the present invention may also include a means for adjusting this distance comprising a retractable stalk 75 attached to the base 67 of the mold 65. As the material is deposited and conforms to the side wall 66, the base 67 is continuously retracted downward so that the distance between the atomizing nozzle 62 and the surface 70 of the preform 72 is maintained. Retraction of the base 67 downward exposes a portion of the walls of the solidified preform below the wall 66 of the mold 65.

(27) Although only a single combination of a CIG and nucleated casting apparatus is included in the apparatus 10, it is contemplated that multiple atomizing spray apparatuses or multiple combinations of a melting and refining apparatus (such as an ESR apparatus) with an atomizing spray apparatus feeding a single casting mold may be advantageous. For example, a system employing multiple transfer apparatus/atomizing nozzle combinations downstream of a single ESR apparatus would permit ingots of greater diameters to be manufactured because the multiple atomized sprays may cover a greater area in the mold. In addition, process rates would increase and costs would be reduced. Alternatively, a single or multiple ESR or other melting and refining apparatuses may feed multiple atomizing nozzles directed at several molds so as to create multiple preforms from a single feed electrode supplied to the melting and refining apparatus.

(28) Other possible modifications to the above-described apparatus 10 of the invention include: adapting the nucleated casting apparatus 60 so as to rotate the nucleated casting cast preform 72 during processing to give a more even distribution of the droplet spray over a large surface; the use of multiple atomizing nozzles to feed a single mold; and equipping the apparatus 10 so that the one or more atomizing nozzles can oscillate. As noted above, a VAR apparatus is one melting and refining apparatus that may be used in place of the ESR apparatus 20 to melt the consumable electrode 24. In VAR, the consumable electrode is melted by application of DC current and does not pass through a conductive slag.

(29) Another possible modification to the apparatus 10 is to incorporate a member having a passage therethrough and constructed with walls of ceramic or other suitable refractory material as the transfer apparatus in place of the CIG 40 to transfer the material melted in the ESR apparatus 20 (or other melting and refining apparatus) to the nucleated casting apparatus 60. In various cases, the passage within the transfer apparatus would not be associated with means to heat the material passing therethrough and, accordingly, there would be less flexibility in regulating the flow of the molten material to the nucleated casting apparatus 60. In other various cases, however, supplemental heating could be provided to the refractory via induction coils or resistance heating, combustion heating or any other suitable heating mechanism.

(30) The apparatus 10 also may be adapted to modify the manner of withdrawal of the preform 72 and to maintain acceptable surface finish on the preform 72. For example, the apparatus 10 may be constructed so that the casting mold 65 reciprocates (i.e., the mold moves up and down), the casting mold 65 oscillates, and/or the preform 72 reciprocates in a manner similar to that used in conventional continuous casting technology. Another possible modification is to adapt the apparatus such that the one or more atomizing nozzles move to raster the spray and increase coverage on the surface of the preform. The apparatus may be programmed to move the one or more nozzles in any suitable pattern.

(31) Also, to better ensure minimizing porosity in the preform, the chamber in which the nucleated casting occurs may be maintained at partial vacuum such as, for example, to atmosphere. Maintaining the chamber under partial vacuum also has the advantage of better maintaining the purity of the material being cast. The purity of the material also may be maintained by conducting the casting in a protective gas atmosphere. Suitably protective gases include, for example, argon, helium, hydrogen, and nitrogen.

(32) Although the foregoing description of the casting apparatus 10 refers to the melting and refining apparatus (ESR apparatus 20), transfer apparatus (CIG 40), and nucleated casting apparatus 60 as relatively discrete apparatuses associated in series, it will be understood that the apparatus 10 need not be constructed in that way. Rather than being constructed of discrete, disconnectable melting/refining, transfer, and casting apparatuses, the apparatus 10 may incorporate the essential features of each of those apparatuses without being capable of deconstruction into those discrete and individually operable apparatuses. Thus, reference in the appended claims to a melting and refining apparatus, a transfer apparatus, and a nucleated casting apparatus should not be construed to mean that such distinct apparatuses may be disassociated from the claimed apparatus without loss of operability.

(33) The following computer simulations and actual examples confirm advantages provided by the apparatus and method of the present invention.

Example 1Computer Simulation

(34) Computer simulations show that preforms prepared by the apparatus 10 of the invention will cool significantly faster than ingots produced by conventional processing. FIGS. 3A and 3B (mass flow rate to caster of 0.065 kg/sec. or about 8.5 lb/min.) and FIGS. 4A and 4B (mass flow rate to caster of 0.195 kg/sec.) illustrate the calculated effects on the temperature and liquid volume fraction of a preform cast by the apparatus 10 of the present invention using the parameters shown in Table 1 below.

(35) TABLE-US-00001 TABLE 1 Parameters of Simulated Castings Preform Geometry Cylindrical 20 inch (508 mm) preform diameter Inflow region constitutes entire top surface of preform Nucleated Casting Apparatus Operating Conditions Mass flow rates of 0.065 kg/sec. (as reported in the reference of footnote 1 below for a comparable VAR process) (FIGS. 3A and 3B) and 0.195 kg/sec. (FIGS. 4A and 4B) 324 K (51 C.) average temperature of the cooling water in the mold. 324 K (51 C.) effective sink temperature for radiation heat loss from the ingot top surface. Alloy flowing into the mold is at the liquidus temperature of the alloy. Heat loss coefficients due to convection from the top surface of preform as per E. J. Lavernia and Y. Wu., Spray Atomization and Deposition (John Wiley & Sons., 1996), pp. 311-314, with gas-to-metal ratio of 0.2, and side surface 0 W/m.sup.2K. The disclosure of the Lavernia and Wu reference is hereby incorporated herein by reference. Preform Material and Thermophysical Properties Alloy 718. Liquidus and solidus temperatures of 1623 K and 1473 K, respectively (as reported in the reference of footnote 1 below). Emmissivities of 0.05 (top surface) and 0.2 (side surface). Model for Heat Transfer to Mold The model for heat transfer to the mold is that described in the reference of n. 1, wherein the heat transfer boundary condition transitions linearly from a full contact condition for surface preform temperatures greater than the liquidus temperature to a gap heat transfer condition for surface temperatures less than the solidus temperature. 20 inc (508 mm) diameter mold. .sup.1L. A. Bertram et al., Quantitative Simulations of a Superalloy VAR Ingot at the Macroscale, Proceedings of the 1997 International Symposium on Liquid Metal processing and Casting, A. Mitchell and P. Auburtin, eds. (Am. Vac. Soc., 1997). The reference is hereby incorporated herein by reference.

(36) The isotherm data provided graphically in FIGS. 3A, 3B, 4A, and 4B demonstrates that the surface temperature of the preform produced in the simulations is below the liquidus temperature of the alloy. The maximum preform temperatures calculated for FIGS. 3A and 4A are 1552 K and 1600 K, respectively. Therefore, the pool under the spray will be semi-solid, and the semi-solid nature of the pool is shown by the liquid fraction data that is graphically shown in FIGS. 3B and 4B.

(37) Table 2 below compares certain results of the computer simulations with typical results of a VAR casting of a preform of similar size reported in the reference of n. 1. Table 2 shows that the pool of material on the surface of a preform prepared by the apparatus 10 of the present invention may be semi-solid, while that produced by conventional VAR processing is fully liquid up to 6 inches below the surface. Thus, for a given preform size, there is substantially less latent heat to be removed from the region of solidification of a preform cast by an apparatus constructed according to the present invention. That, combined with the semi-solid nature of the pool, will minimize microsegregation and the possibility of freckle formation, center segregation, and other forms of detrimental macro segregation. In addition, the present invention also completely eliminates the possibility of white spot defect formation, a defect inherent in the VAR process.

(38) TABLE-US-00002 TABLE 2 Comparison Of Invention With VAR Cast Ingot Maximum Maximum Liquid Surface Pool Volume Temp. Depth (depth Fraction Process K ( F.) of liquidus at axis) on Surface Simulation @ 8.5 lbs./ 1552 K 0 inches 0.52 minute mass (2334 F.) flow rate (20 diameter preform formed by nucleated casting) Simulation @ 25.5 lbs./ 1600 K 0 inches 0.85 minute mass (2421 F.) flow rate (20 diameter preform formed by nucleated casting) Standard VAR @ 1640 K 6 inches 1 8.5 lbs./minute mass (2493 F.) flow rate (20 diameter ingot formed)

Example 2Trial Casting

(39) A trial casting using an apparatus constructed according to the invention was performed. The apparatus 100 is shown schematically in FIG. 5 and, for purposes of understanding its scale, was approximately thirty feet in overall height. The apparatus 100 generally included ESR head 110, ESR furnace 112, CIG 114, nucleated casting apparatus 116, and material handling device 118 for holding and manipulating the mold 120 in which the casting was made. The apparatus 100 also included ESR power supply 122 supplying power to melt the electrode, shown as 124, and CIG power supply 126 for powering the induction heating coils of CIG 114.

(40) ESR head 110 controlled the movement of the electrode 124 within ESR furnace 112. ESR furnace 112 was of a typical design and was constructed to hold an electrode of approximately 4 feet in length by 14 inches in diameter. In the case of the alloy used in the trial casting, such an electrode weighed approximately 2500 pounds. ESR furnace 112 included hollow cylindrical copper vessel 126 having view ports 128 and 130. View ports 128 and 130 were used to add slag (generally shown as 132) to, and to assess the temperature within, ESR furnace 112. CIG 114 was about 10 in vertical length and was of a standard design including a central bore for passage of molten material surrounded by copper walls including coolant circulation passages. The copper walls were, in turn, surrounded by induction heating coils for regulating the temperature of the material passing through CIG 114.

(41) Nucleated casting apparatus 116 included chamber 136 surrounding mold 120. Chamber 136 enclosed mold 120 in a protective nitrogen atmosphere in which the casting was carried out. The walls of chamber 136 are shown transparent in FIG. 5 for purposes of viewing mold 120 and its associated equipment within chamber 136. Mold 120 was held at the end of robot arm 138 of material handling device 118. Robot arm 138 was designed to support and translate mold 120 relative to the spray of molten material, shown generally as 140, emanating from the nozzle of nucleated casting apparatus 116. In the trial casting, however, robot arm 138 did not translate the mold 120 during casting. An additional advantage of chamber 136 is to collect any overspray generated during casting.

(42) The supplied melt stock was a cast and surface ground 14 inch diameter VIM electrode having a ladle chemistry shown in Table 3. The electrode was electroslag remelted at a feed rate of 33 lbs./minute using apparatus 100 of FIG. 5. The slag used in the ESR furnace 112 had the following composition, all components shown in weight percentages: 50% CaF.sub.2, 24% CaO, 24% Al.sub.2O.sub.3, 2% MgO. The melt refined by the ESR treatment was passed through CIG 114 to nucleated casting apparatus 116. CIG 114 was operated using gas and water recirculation to regulate temperature of the molten material within the CIG 114. Argon gas atomization was used to produce the droplet spray within nucleated casting apparatus 116. The minimum 0.3 gas-to-metal ratio that could be used with the atomizing nozzle incorporated into the nucleated casting apparatus 116 was employed. The atomized droplets were deposited in the center of mold 120, which was a 16 inch diameter, 8 inch depth (interior dimensions) uncooled 1 inch thick steel mold with Kawool insulation covering the mold baseplate. As noted above, mold 120 was not rastered, nor was the spray cone rastered as the preform was cast.

(43) Centerline plates were cut from the cast preform and analyzed. In addition, a 2.52.55 inch section from the mid-radius position was upset forged from 5 inches to 1.7 inches height at 1950 F. to enhance etch inspectability for macro segregation. The chemistry of the cast preform at two positions is provided in Table 3.

(44) TABLE-US-00003 TABLE 3 Ladle and Cast Preform Chemistry Preform Ladle Preform Chemistry Chemistry Chemistry (Center) (Near Surface) Ni 53.66 53.85 53.65 Fe 17.95 18.44 18.41 Cr 17.95 18.15 18.17 Nb 5.44 5.10 5.16 Mo 2.86 2.78 2.79 Ti 0.98 0.86 0.87 Al 0.55 0.59 0.61 V 0.02 0.02 0.02 Co 0.02 0.05 0.05 Cu 0.01 0.05 0.05 Mn <0.01 0.03 0.03 Si <0.01 0.01 0.02 W <0.01 <0.01 <0.01 Ta <0.01 <0.01 <0.01 Zr <0.01 <0.01 <0.01 P <0.003 0.004 0.003 S 0.0008 <0.0003 <0.0003 O 0.0006 0.0008 0.0008 N 0.0018 0.0038 0.0042 C 0.024 0.023 0.022

(45) A tin addition was made to the molten ESR pool at the fourteenth minute of the fifteen-minute spraying run to mark the liquidus pool depth. The tin content was measured every 0.25 inch after deposition. The measured distance between the liquidus and solidus boundaries was estimated to be 4-5 inches. This confirmed the shallow melt pool predicted by the model described in Example 1. Visual inspection of the preform revealed certain defects indicating that the deposited material required additional fluidity to fill the entire mold. No attempt was made to hot top the preform by reducing the gas-to-metal ratio or pouring the stream of metallic material without atomization. Suitable adjustment to the deposition process may be made in order to inhibit formation of defects within the preform.

(46) The as-sprayed structure of the preform produced by the above nucleated casting process and an as-cast micrograph from a 20 inch diameter VAR ingot of the same material are shown in FIGS. 6 and 7, respectively. The nucleation cast (NC) preform (FIG. 6) possesses a uniform, equiaxed ASTM 4.5 grain structure with Laves phase present on the grain boundaries. phase also appears at some grain boundaries, but probably precipitated during a machining anneal conducted on the cast preform material. The VAR ingot includes a large grain size, greater Laves phase volume, and larger Laves particles than the spray cast material (>40 m for VAR vs. <20 m for spray cast).

(47) Macrosegregation-related defects such as white spots and freckles were not observed in the preform. A mult was upset forged to refine grain structure and aid in detection of defects. A macro plate from the forging did not reveal any macrosegregation defects. The oxide and carbide dispersions of the preform material were refined relative to VAR ingot material and were similar to that found in spray formed material. Carbides were less than 2 micrometers and oxides were less 10 micrometers in size in the preform. Typically, 20 inch diameter preforms of alloy 718 cast by conventional VAR have carbides of 6-30 microns and oxides of 1-3 microns up to 300 microns in the microstructure. The carbides and oxides seen in material cast by the present invention are typical of those seen in spray forming, but are finer (smaller) than those seen in other melt processes such as VAR. These observations confirm that more rapid solidification occurs in the method of the invention than in conventional VAR ingot melting of comparably sized ingots, even though the method of the invention typically uses a much higher casting rate than VAR.

(48) The chemistry analyses shown in Table 3 do not reveal any elemental gradients. In particular, no niobium gradient was detected in the preform. Niobium is of particular interest because migration of that element from the preform surface to the center has been detected in spray formed ingots. Table 3 does demonstrate differences between the ladle chemistry and ingot chemistry for the preform. Those differences are attributed to porosity in the preform samples used in the XRF procedure rather than actual difference in chemistry.

(49) Based on the results of the experimental casting, a lower gas-to-metal ratio is desirable to enhance mold fill and inhibit porosity problems. Use of a more fluid spray may increase microsegregation to some extent, but the wide beneficial margin exhibited in the trial over VAR should accommodate any increase. Grain size also may increase with increasing fluidity, but the constant impingement of new droplets provides a high density of grain nucleation sites to inhibit formation of large or columnar grains within the preform. Greater spray fluidity would significantly enhance the ability of the droplets to fill the mold, and a more fluid impingement zone would reduce sidewall rebound deposition. An additional advantage of a more fluid impingement zone is that the atomizing gas will more readily escape the material and a reduction in porosity will result. To enhance outgassing of the atomizing gas from the preform surface, the casting may be performed in a partial vacuum such as, for example atmosphere. Any increase in size of carbides and oxides resulting from reducing the gas-to-metal ratio is expected to be slight. Thus, an advantageous increase in fluidity of the droplet spray is expected to have only minor effects on grain structure and second phase dispersion.

(50) Accordingly, the apparatus and method of the present invention address significant deficiencies of current methods of casting large diameter preforms from alloys prone to segregation. The melting and refining apparatus provides a source of refined molten alloy that is essentially free from deleterious oxides. The transfer apparatus provides a method of transferring the refined molten alloy to the nucleated casting apparatus with a reduced possibility of oxide recontamination. The nucleated casting apparatus may be used to advantageously form small grained, large diameter ingots from segregation prone alloys without the casting-related defects associated with VAR and/or spray casting.

(51) As described above, and referring to FIGS. 2, 8 and 9, a nucleated casting apparatus according to the present invention can include a mold and an atomizing nozzle configured to direct a droplet spray of a molten material into the mold. In various embodiments, as described above, the mold can include a base and a side wall, wherein the base can be moved relative to the side wall. In one exemplary embodiment, referring to FIG. 2, nucleated casting apparatus 60 can include mold 65 comprising base 67 and side wall 66, wherein base 67 can be moved relative to side wall 66. Similarly, referring to FIGS. 8 and 9, nucleated casting apparatus 260 can include mold 265 comprising base 267 and side wall 266. In these embodiments, as described above, a preform, such as preform 72, for example, can be created within the mold and can be withdrawn downwardly, for example, to facilitate the continuous casting of the preform. In various embodiments, referring to FIG. 9, a preform created within mold 265 can be moved along axis 263 relative to side wall 266.

(52) In various embodiments, referring to FIG. 2, the droplet spray produced by the atomizing nozzle can be entirely captured within the mold. In various other embodiments, referring to FIGS. 8 and 9, at least a portion of the droplet spray, i.e., overspray 280, can accumulate on side wall 266. In some circumstances, overspray 280 and a preform being cast within mold 265 can be become welded together as they solidify. As a result, the preform can become locked to side wall 266, for example, preventing or inhibiting the preform from being withdrawn downwardly with respect to side wall 266 by base 267. In these circumstances, the nucleated casting process may have to be stopped to remove overspray 280. Even after overspray 280 has been removed, it may not be possible to restart the nucleated casting process as the top surface of the preform may have solidified while overspray 280 was being removed. In this event, the preform may have to be removed from mold 265 before the desired length of the preform has been reached.

(53) In various embodiments, referring to FIG. 9, the atomizing nozzle, such as nozzle 262, may be oriented such that droplet spray 264 passes over top surface 269 of side wall 266. In passing over top surface 269, droplet spray 264 may or may not contact side wall 266. In either event, droplet spray 264 can remelt at least a portion of overspray 280 and to some degree prevent overspray 280 from accumulating on side wall 266. As a result of the angular orientation of droplet spray 264 relative to axis 263, overspray 280 may not become welded to the preform or, at the very least, the removal of at least a portion of overspray 280 may sufficiently delay such welding until after the minimum desired length of the preform has been reached. As a result, a nucleated casting apparatus including the configuration described above may improve the efficiency of the casting process as the casting process may have to be stopped less often, or not at all, to remove the overspray.

(54) In various circumstances, overspray may accumulate on several regions of top surface 269 which are located outside of droplet spray 264. To remelt this overspray, atomizing nozzle 262 may be oscillated and/or rastered, as described above, such that droplet spray 264 contacts the overspray accumulated on various regions of top surface 269. In at least one embodiment, the casting apparatus may include two or more atomizing nozzles, each of which can be configured to produce a droplet spray which can remelt portions of the overspray at various locations around the perimeter of top surface 269. In various embodiments, all or various portions of mold 265 can be rotated such that the perimeter of top surface 269 can pass under droplet spray 264 and the overspray on substantially every region, if not every region, of top surface 269 can be removed. In various embodiments, atomizing nozzle 262 may be configured such that it produces a droplet spray having an axis, such as axis 271, for example, which is oriented in a direction that is at an angle with axis of rotation 263 of mold 265. In such embodiments, the droplet spray may or may not be symmetrical about axis 271. In either event, directions at an angle with axis of rotation 263 can include directions which are skew with respect to axis 263 and/or directions which intersect axis 263. In other various embodiments, atomizing nozzle 262 may be configured to direct droplet spray 264 in a direction which is neither parallel to nor perpendicular with axis of rotation 263.

(55) As described above, a nucleated casting assembly in accordance with an embodiment of the present invention can include a casting mold wherein all or various portions of the mold can be rotated about an axis of rotation where the mold can include a base relatively movable with respect to a side wall. In at least one such embodiment, referring to FIGS. 8 and 9, nucleated casting assembly 260 can include ram 276 which can be configured to rotate mold 265 about axis 263 and, in addition, translate base 267 along axis 263 relative to side wall 266. In order to raise and lower base 267 relative to side wall 266, base 267 can be mounted to ram 276 via stalk 275, stub adapter 277 and clamp 278, where clamp 278 can be configured to mount stalk 275 and stub adapter 277 to ram 276 such that, when ram 276 is moved along axis 263, base 267 is moved relative to side wall 266.

(56) In order to rotate mold 265 about axis 263, ram 276 can be rotationally coupled with base 267 and side wall 266. In various embodiments, referring to FIGS. 8 and 9, stub adapter 277 and stalk 275 can be engaged with ram 276 such that the rotational motion of ram 276 is transmitted into base 267. In at least one embodiment, although not illustrated, stub adapter 277 and ram 276 can include key and groove features which are configured to transmit rotational motion therebetween. Stub adapter 277 and stalk 275 can include similar key and groove features, although other features are contemplated including a clutch mechanism which may limit the torque transmitted between stub adapter 277 and stalk 275. In either event, ram 276 may be continuously rotated in one direction or, in various embodiments, ram 276 can be oscillated or selectively rotated in opposite directions.

(57) In various embodiments, nucleated casting apparatus 260 can further include rails 282 which are configured to transmit rotational motion between ram 276 and side wall 266. More particularly, stalk 275 can include slots 279 and side wall 266 can include recesses 281 which are configured to receive rails 282 such that the rotational motion of ram 276 can be transmitted to side wall 266 through the engagement of rails 282 with the side walls of slots 279 and recesses 281. In such embodiments, as a result, side wall 266 and base 267 can be rotated at the same rotational speed with substantially no relative rotational movement therebetween. Although not illustrated, other embodiments are envisioned, however, where one of side wall 266 and base 267 is not rotated or both are rotated but at different speeds. Furthermore, although two guide rails 282 are illustrated in the exemplary embodiment, other embodiments are envisioned which include one guide rail or more than two guide rails. In at least one embodiment, although not illustrated, the side wall of the mold can include a top portion which moves relative to the droplet spray, as described above, and a bottom portion which is stationary. In such an embodiment, a bearing can be positioned between the top and bottom portions to facilitate relative movement therebetween.

(58) In various embodiments, referring to FIGS. 8 and 9, rails 282 can transmit rotational movement to side wall 266 from ram 276 without transmitting translational movement thereto. More particularly, when ram 276 lowers base 267, stalk 275 can slide down rails 282 permitting relative translational movement therebetween. As a result, base 267 can be moved relative to side wall 266 along axis 263 as described above. In at least one embodiment, referring to FIG. 9, nucleated casting apparatus 260 can further include mounting bracket 283 which can be configured to support side wall 266. More particularly, side wall 266 can include flange, or bearing surface, 284 extending from side wall 266 which is configured to rest on, and be rotatably supported by, mounting bracket 283. In various embodiments, casting apparatus 260 can further include a bearing for facilitating relative rotational movement between side wall 266 and mounting bracket 283 when side wall 266 is rotated as described above. In at least one embodiment, although not illustrated herein, casting apparatus 260 can include a bearing ring positioned between bearing surface 284 and bracket 283. This bearing ring can be comprised of any suitable material including, for example, brass. In various embodiments, mounting bracket 283 can include track 285 which is configured to receive ball bearings 286. In use, ball bearings 286 can facilitate relative rotational movement between side wall 266 and bracket 283 by reducing the friction forces therebetween.

(59) As described above, relative movement between the mold of a nucleated casting apparatus and the atomizing nozzle can facilitate the removal of overspray accumulated on the side wall of the mold, for example. As described above, the mold can be rotated about an axis such that various portions of the top surface of the side wall can pass under a droplet spray created by the atomizing nozzle. In various embodiments, the nucleated casting apparatus can include an automated system which detects the presence of overspray on the side wall and selectively rotates the mold such that the overspray passes through the droplet spray. Such an automated system can include a camera, for example, which can detect the presence of overspray on the side wall, and a computer which processes data received from the camera and transmits a signal to a motor operably coupled with the ram of the casting apparatus to rotate the mold. In at least one embodiment, the automated system can include an indexing system which rotates the mold a predetermined amount after a predetermined increment of operational time has elapsed. In either event, the nucleated casting apparatus can include controls which can be manually operated to rotate the mold.

(60) Although not illustrated, embodiments are envisioned where the atomizing nozzle can be moved relative to the mold. In various embodiments, as described above, the nozzle can be oscillated such that the direction of the droplet spray can be changed relative to the mold. In further embodiments, the atomizing nozzle can be rotated about the nucleated casting mold. In these embodiments, the nozzle can be rotated about an axis of rotation, for example, such that the droplet spray produced by the nozzle passes over various portions of the top surface of the side wall. As a result, as described above, at least a portion of the overspray accumulated on top of the mold can be remelted and prevented from welding with the preform being cast in the mold. In these embodiments, similar to the above, the base of the mold can be moved relative to the side wall to withdraw the preform along a withdrawal axis, for example, as the atomizing nozzle is rotated about the mold. Furthermore, similar to the above, these nucleated casting systems can include controls for selectively rotating the nozzle which can be automatically and/or manually operated.

(61) The foregoing features of an angularly oriented droplet spray and a rotatable mold having relatively movable portions may be included in various casting and refining devices according to the present invention as described herein. One or all of these features may also be included in any conventional or otherwise known design for a nucleated casting apparatus and can provide the advantages described above. Accordingly, it will be understood that a nucleated casting apparatus including the features of an angularly oriented droplet spray and/or a rotating mold having relatively movable portions need not be combined with other elements of the casting and refining apparatus described herein.

(62) It is to be understood that the present description illustrates those aspects of the invention relevant to a clear understanding of the invention. Certain aspects of the invention that would be apparent to those of ordinary skill in the art and that, therefore, would not facilitate a better understanding of the invention have not been presented in order to simplify the present description. Although the present invention has been described in connection with certain embodiments, those of ordinary skill in the art will, upon considering the foregoing description, recognize that many modifications and variations of the invention may be employed. All such variations and modifications of the invention are intended to be covered by the foregoing description and the following claims.