Method of casting an article

B - Operations – Transporting – 22 – D

Patent

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B22D 19/00 (2006.01) B22D 27/04 (2006.01) C30B 11/00 (2006.01)

Patent

CA 1202466

Abstract of the Disclosure An airfoil containing metal article is cast with portions having unit cells with different or orientations. The leading and trailing edge portions of the airfoil are cast with cubic unit cells having an [001] direction extending substantially parallel to the longitudinal axis of the article in order to promote thermal fatigue resistance. The central portion of the airfoil has unit cells with a [111] orientation with respect to the longitudinal axis in order to improve the creep strength and Young's modulus of the airfoil. The leading and trailing edge portions and central portion of the airfoil may be cast with elongated crystals or may be cast with each of the portions formed as a single crystal. To cast the airfoil containing metal article, a starter element having portions with unit cells oriented in different directions is placed in an open end portion of a mold with the starter element exposed to both a mold cavity and a chill. Molten metal is poured against the starter element and crystals are nucleated with unit cells having orientations corresponding to the orientations of the unit cells in the portion of the starter element engaged by the molten metal. The molten metal which is solidified to form the leading and trailing edge portions of an airfoil engages a portion of the starter element in which the unit cell s have [001] orientations with respect to the longitudinal axis of the airfoil. The molten metal which is solidified to form the central portion or the airfoil engages a portion of the starter element which has unit cells oriented in a [111] direction with respect to the longitudinal axis of the airfoil.

404563

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