Sulzer-mtu Casting Technology Gmbh

Sulzer Brothers Limited

Sulzer Innotec Ag

Fritz Staub

Jurgen Wortmann

Bruno Walser

Robert Wege

Daniel Stahl

The cast part (,) comprises a basic body (,) of a first material and a coating of at least one second material. The second material is applied to a co-cast skeleton structure (,) on the surface (,) of the basic body, with it forming a covering (,) or a covering layer (,).

Coated cast part

A casting unit for the manufacturing of a plurality of cast parts by using directed solidification or monocrystal formation as well as the process for casting is provided. A plurality of individual molds are combined while forming close distances to form a mold shell in the manner of an array. In this manner, the simultaneous casting of a large number of cast parts is permitted while the space requirement is minimized.

Casting unit for the manufacturing of a plurality of cast parts

A process for the production of castings by directional or monocrystalline solidification is carried out in a vacuum casting plant which, apart from a conventional cooling plate, has no additional heating devices for the casting mold. The unidirectional heat flow required to guide the solidification front is produced on the one hand, by heat sources formed partially from superheated melt and, on the other hand, by heat sinks consisting of the cooling plate and the surroundings of the mold. The mold is heated in a separate heating-up oven to a temperature above the liquidus temperature of the melt in order that the casting mold may contribute to the heat source in addition to the melt so doing.

Casting process for the production of castings by directional or

A process and apparatus for the production of a single-crystal article, such as a turbine blade, by casting a molten metal into a casting mold with a single crystal seed crystal at the bottom of the casting mold. The casting mold is heated and vacuum-purified after which the seed crystal is introduced into an opening at the bottom of the mold in a matter of a few seconds whereafter the molten metal is immediately cast onto the seed crystal in the casting mold. The seed crystal is carried by a holder which is lifted to bring the seed crystal into the open bottom of the casting mold in sealed relation in the mold.

Process and apparatus for production of single-crystal turbine blades

A process and apparatus for the repair of single-crystal drive blades, such as turbine blades, in which a sound portion of the blade is inserted into an open bottom of a casting mold in communication with a casting cavity in the mold adopted to the shape of the blade. The molten metal is then cast into the mold to unite with the sound portion and an epitaxial single-crystal solidification of the melt is produced on the sound portion to form the entire blade. A part of the sound portion has an outer surface layer thereof removed to expose a core region which is constituted of substantially pure single crystal material prior to casting. The sound part is secured in a holder which is coupled to the casting mold for only a matter of seconds before the molten metal is cast into the mold.

Process and apparatus for repair of drive blades such as turbine blades

The apparatus for the production of directionally solidified castings (10) in a vacuum casting plant comprises a cooling attachment with members (60) between a flat cooling plate (6) and the mold shell (2), by means of which member zones of different orientation of the direction of solidification can be produced in the casting. This apparatus is particularly suitable for the production of components in the form of a wheel--e.g. turbine wheels in aircraft jet engines--in which a radial alignment of the texture structure is advantageous in order to increase strength.

Apparatus for the production of directionally solidified castings

A process for the repair of single-crystal drive blades, such as turbine blades, in which a sound portion of the blade is inserted into an open bottom of a casting mold in communication with a casting cavity in the mold adopted to the shape of the blade. The molten metal is then cast into the mold to unite with the sound portion and an epitaxial single-crystal solidification of the melt is produced on the sound portion to form the entire blade. A part of the sound portion has an outer surface layer thereof removed to expose a core region which is constituted of substantially pure single crystal material prior to casting. The sound part is secured in a holder which is coupled to the casting mold for only a matter of seconds before the molten metal is cast into the mold.

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Seuzach, Switzerland

Fritz Staub