Die casting system and method utilizing high melting temperature materials

Abstract

An example die casting system includes a die comprised of a plurality of die components that define a die cavity configured to receive a molten metal. One of the die components comprises a material that is not reactive with the molten metal and has a melting temperature above 815 degrees Celsius. The die casting system may be used in a method for die casting a gas turbine engine component.

We claim: 
     
         1 . A method for die casting a gas turbine engine component, comprising:
 melting a metallic material to form a molten metal,   wherein the molten metal is comprised of a non-nickel based material,   wherein the non-nickel based material includes a high temperature aluminum alloy, a copper based alloy, molybdenum, tungsten, niobium, rhenium, or tantalum;   communicating the molten metal within a shot tube of a die casting system;   injecting the molten metal under pressure from the shot tube into a die cavity of a die of the die casting system,   wherein the die is comprised of a plurality of die components that define the die cavity,   wherein at least one of the plurality of die components comprises a material that is not reactive with the molten metal and has a melting temperature above 815 degrees Celsius,   wherein the material of the at least one of the plurality of die components includes a nickel based super alloy, a cobalt based super alloy, or a refractory metal based alloy selected from a group consisting of rhenium, niobium, and tantalum; and   solidifying the molten metal within the die cavity to form the gas turbine engine component.   
     
     
         2 . The method as recited in  claim 1 , wherein the die casting system includes a shot tube plunger moveable within the shot tube to inject the molten metal into the die cavity. 
     
     
         3 . The method as recited in  claim 2 , wherein the shot tube or the shot tube plunger comprises the material of the at least one of the plurality of die components. 
     
     
         4 . The method as recited in  claim 2 , wherein a tip of the shot tube plunger comprises the material of the at least one of the plurality of die components. 
     
     
         5 . The method as recited in  claim 1 , wherein the die casting system includes an ejector pin configured to be moved relative to the die cavity, wherein the ejector pin comprises the material of the at least one of the plurality of die components. 
     
     
         6 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components is the nickel based super alloy and is selected from a group consisting of IN100, IN713C, IN792 forged, first generation nickel based single crystal alloys (0% Rhenium), second generation nickel based single crystal alloys (3% Rhenium), third generation nickel based single crystal alloys (6% Rhenium), fourth generation nickel based single crystal alloys (6% Rhenium, 3% Ruthenium), fifth generation nickel based single crystal alloys (6+% Rhenium, 6+% Ruthenium), directionally solidified first generation (0% Rhenium) columnar structure nickel based alloys, and second generation (3% Rhenium) columnar structure nickel based alloys. 
     
     
         7 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components is IN100, IN713C, or IN792 forged. 
     
     
         8 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components includes a first generation nickel based single crystal alloys (0% Rhenium). 
     
     
         9 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components includes a second generation nickel based single crystal alloys (3% Rhenium). 
     
     
         10 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components includes a third generation nickel based single crystal alloys (6% Rhenium). 
     
     
         11 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components includes a fourth generation nickel based single crystal alloys (6% Rhenium, 3% Ruthenium). 
     
     
         12 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components includes a fifth generation nickel based single crystal alloys (6+% Rhenium, 6+% Ruthenium). 
     
     
         13 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components includes a directionally solidified first generation (0% Rhenium) columnar structure nickel based alloys. 
     
     
         14 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components includes a second generation (3% Rhenium) columnar structure nickel based alloys. 
     
     
         15 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components includes Mar-M-509 or and Stellite 31. 
     
     
         16 . The method as recited in  claim 1 , wherein the material of the at least one of the plurality of die components includes Anvilloy 1150, TZM (tungsten-molybdenum-zirconium), molybdenum-rhenium systems, tantalum-10% tungsten, and tungsten-rhenium. 
     
     
         17 . The method as recited in  claim 1 , wherein another one of the plurality of die components is made of a second material that is different from the material of the at least one of the plurality of die components. 
     
     
         18 . The method as recited in  claim 1 , wherein a coating of the material of the at least one of the plurality of die components is applied to an internal surface of the die cavity. 
     
     
         19 . The method as recited in  claim 1 , wherein the non-nickel based material includes tungsten or molybdenum. 
     
     
         20 . The method as recited in  claim 1 , wherein the non-nickel based material includes niobium, rhenium, or tantalum.