Unit Cell Titanium Casting

Abstract

A system ( 5 ) and method ( 800 ) for unit cell casting of titanium or titanium-alloys is disclosed herein. The system ( 5 ) comprises an external chamber ( 45 ), a crucible ( 10 ) positioned within the external chamber ( 45 ), an induction coil ( 15 ) positioned around the crucible, an internal chamber ( 40 ) positioned within the external chamber ( 45 ), and a mold ( 30 ) positioned within the internal chamber ( 40 ). The external chamber ( 45 ) is evacuated and a pressurized gas is injected into the evacuated external chamber ( 45 ) to create a pressurized external chamber ( 45 ). An ingot ( 20 ) is melted within the crucible utilizing induction heating generated by the induction coil ( 15 ). The internal chamber ( 40 ) is evacuated to create an evacuated internal chamber ( 40 ). The titanium alloy material of the ingot ( 20 ) is completely transferred into the mold ( 30 ) from the crucible ( 10 ) using a pressure differential created between the external chamber ( 45 ) and the internal chamber ( 40 ).

We claim as our invention the following: 
     
         1 . A method for unit cell casting of titanium or titanium-alloys, the method comprising:
 positioning a mold within an internal chamber;   evacuating an external chamber to create an evacuated external chamber wherein a ceramic crucible containing a titanium alloy ingot is positioned therein;   evacuating the internal chamber to create an evacuated internal chamber having a pressure no greater than 3×10 −2  atmosphere;   injecting a pressurized gas into the evacuated external chamber to create a pressurized external chamber with a pressure in excess of 1 atm;   melting the titanium alloy ingot within the ceramic crucible utilizing induction heating generated by an induction coil to superheat the titanium alloy material in excess of its melting temperature;   transferring the completely melted titanium alloy material into the mold from the crucible using a pressure differential created between the external chamber and the internal chamber;   wherein the crucible is not cooled;   wherein a high pressure differential in maintained between the external chamber and the internal chamber during the transfer of the melted titanium alloy material;   wherein the PLC controls power to the induction coil to position the induction coil relative to the titanium alloy ingot;   wherein the pressure of the internal chamber and the pressure of the external chamber are monitored and communicated to the PLC during the casting process, and wherein the PLC controls the casting process based on the pressure of the internal chamber and the pressure of the external chamber.   
     
     
         2 . The method according to  claim 1  wherein the pressurized gas is argon. 
     
     
         3 . The method according to  claim 1  wherein the centering feature is a seat. 
     
     
         4 . The method according to  claim 1  wherein an atmospheric pressure of the evacuated internal chamber ranges from 3×10 −2  atmosphere to 9.87×10 −7  atmosphere. 
     
     
         5 . The method according to  claim 1  wherein the crucible is a single Yttria-based barium infused shell layer having a thickness ranging from 0.015 inch to 0.060 inch, and comprised of a binder with a slurry ratio between 1:1.5 and 1:3.5. 
     
     
         6 . The method according to  claim 1  wherein a power level to the induction coil is more than 70 kiloWatts. 
     
     
         7 . The method according to  claim 1  wherein the centering feature is a plurality of stand-offs in a wall of the ceramic crucible. 
     
     
         8 . The method according to  claim 1  wherein a power level to the induction coil is more than 90 kiloWatts. 
     
     
         9 . The method according to  claim 1  wherein an atmospheric pressure of the evacuated internal chamber ranges from 9.87×10 −7  atmosphere to 9.87×10 −13  atmosphere 
     
     
         10 . A system method for unit cell casting of titanium or titanium-alloys, the system comprising:
 an external chamber;   a ceramic crucible positioned within the external chamber;   an induction centered on the upper third of the titanium alloy ingot in the ceramic crucible;   an internal chamber positioned within the external chamber; and   a mold positioned within the internal chamber;   wherein a ceramic crucible containing a titanium alloy ingot is positioned therein, wherein the titanium alloy ingot is centered within the ceramic crucible using a centering feature;   wherein the pressure of the internal chamber and the pressure of the external chamber are monitored and communicated to the PLC during the casting process, and wherein the PLC controls the casting process based on the pressure of the internal chamber and the pressure of the external chamber;   wherein the external chamber is evacuated to create an evacuated external chamber;   wherein a pressurized gas is injected into the evacuated external chamber to create a pressurized external chamber;   wherein the titanium alloy ingot is melted within the ceramic crucible utilizing induction heating generated by an induction coil to superheat the titanium alloy material in excess of its melting temperature;   wherein the crucible is composed of Silica and coated with a Yttria based slurry and stucco system;   wherein the internal chamber is evacuated to create an evacuated internal chamber;   wherein the titanium alloy material is completely transferred into the mold from the crucible using a maximum pressure differential created between the external chamber and the internal chamber.   
     
     
         2 . A method for unit cell casting of titanium or titanium-alloys, the method comprising:
 positioning a mold within an internal chamber;   pre-heating a titanium alloy ingot;   evacuating an external chamber to create an evacuated external chamber wherein a ceramic crucible containing the pre-heated titanium alloy ingot is positioned therein;   evacuating the internal chamber to create an evacuated internal chamber having a pressure no greater than 3×10 −2  atmosphere;   injecting a pressurized gas into the evacuated external chamber to create a pressurized external chamber with a pressure in excess of 1 atm;   melting the titanium alloy ingot within the ceramic crucible utilizing induction heating generated by an induction coil;   transferring the completely melted titanium alloy material into the mold from the crucible using a pressure differential created between the external chamber and the internal chamber;   wherein a high pressure differential in maintained between the external chamber and the internal chamber during the transfer of the melted titanium alloy material;   wherein the PLC controls power to the induction coil to position the induction coil relative to the titanium alloy ingot;   wherein the pressure of the internal chamber and the pressure of the external chamber are monitored and communicated to the PLC during the casting process, and wherein the PLC controls the casting process based on the pressure of the internal chamber and the pressure of the external chamber.   
     
     
         12 . The method according to claim  11  wherein the pressurized gas is argon. 
     
     
         13 . The method according to claim  11  wherein a frequency generated in the induction coil ranges from 1 kilo-Hertz to 50 kilo-Hertz. 
     
     
         14 . The method according to claim  11  further comprising a plurality of titanium alloy ingots ranging from 2 to 6 ingots. 
     
     
         15 . The method according to  claim 14  wherein each of the plurality of titanium alloy ingots has a thickness ranging from 1 mm to 10 mm, and a height ranging from 2 cm to 20 cm. 
     
     
         16 . The method according to claim  11  wherein the internal chamber is preheated at a temperature ranging from 1150° C. to 1250° C. 
     
     
         17 . The method according to claim  11  wherein a PLC determines when to melt the titanium alloy based on the pressures of the internal chamber and the external chamber. 
     
     
         18 . The method according to claim  11  wherein the PLC determines when to change the pressure of internal chamber and the external chamber. 
     
     
         19 . The method according to claim  11  wherein an atmospheric pressure of the evacuated internal chamber ranges from 9.87×10 −7  atmosphere to 9.87×10 −13  atmosphere 
     
     
         20 . The method according to claim  11  wherein a power level to the induction coil is more than 60 kiloWatts.