High temperature die casting apparatus and method therefor

Abstract

A high temperature die casting system includes a die casting tool that has dies that are adapted for forming a component. The die casting tool is operable to heat and maintain a temperature of the dies above 500° F./260° C. At least a portion of the die casting tool that is exposed for contact with molten die casting material has a substrate and barrier coating on the substrate to protect from the molten die casting material.

1 . A high temperature die casting system comprising:
 a die casting tool having dies adapted for forming a component and being operable to heat and maintain a temperature of the dies above 500° F./260° C., wherein at least a portion of the die casting tool that is exposed for contact with molten die casting material comprises a substrate and barrier coating on the substrate.   
     
     
         2 . The high temperature die casting system as recited in  claim 1 , wherein the barrier coating is alumina. 
     
     
         3 . The high temperature die casting system as recited in  claim 1 , wherein the barrier coating is silicon nitride. 
     
     
         4 . The high temperature die casting system as recited in  claim 1 , wherein the barrier coating is a refractory metal carbide. 
     
     
         5 . The high temperature die casting system as recited in  claim 4 , wherein the refractory metal carbide is hafnium carbide. 
     
     
         6 . The high temperature die casting system as recited in  claim 4 , wherein the refractory metal carbide is zirconium carbide. 
     
     
         7 . The high temperature die casting system as recited in  claim 4 , wherein the refractory metal carbide is selected from a group consisting of titanium carbide, tungsten carbide, niobium carbide, tantalum carbide, rhenium carbide, molybdenum carbide, silicon carbide and combinations thereof. 
     
     
         8 . The high temperature die casting system as recited in  claim 1 , wherein the barrier coating is silicon-aluminum-oxy-nitride (SiAlON). 
     
     
         9 . The high temperature die casting system as recited in  claim 1 , wherein the barrier coating is selected from a group consisting of boron nitride and aluminum nitride. 
     
     
         10 . The high temperature die casting system as recited in  claim 1 , wherein the barrier coating is selected from a group consisting of gadolinia, zirconia, partially or fully stabilized zirconia material, and mixtures thereof. 
     
     
         11 . The high temperature die casting system as recited in  claim 1 , wherein the barrier coating comprises at least one oxide and the balance comprising a first oxide selected from the group consisting of zirconia, ceria, and hafnia, the at least one oxide having a formula A 2 O 3  where A is selected from a group consisting of La, Pr, Nd, Sm, Eu, Th, In, Sc, Y, Dy, Ho, Er, Tm, Yb, Lu, and mixtures thereof. 
     
     
         12 . The high temperature die casting system as recited in  claim 1 , wherein the barrier coating includes a metallic coating selected from a group consisting of ruthenium, rhodium, palladium, osmium, iridium, platinum and combinations thereof. 
     
     
         13 . The high temperature die casting system as recited in  claim 1 , wherein the barrier coating is a nickel alloy consisting essentially of up to 15 wt % cobalt, 5-18 wt % chromium, 7.5-12 wt % aluminum, 0.1-1.0 wt % yttrium, up to 0.06 wt % hafnium, up to 0.3 wt % silicon, 3-10 wt % tantalum, up to 5 wt % tungsten, 1-6 wt % rhenium, up to 10 wt % molybdenum, and a balance of nickel and any impurities. 
     
     
         14 . The high temperature die casting system as recited in  claim 1 , further comprising a bond coat between the substrate and the barrier coating, and the bond coat is a material selected from a group consisting of MCrAlY, gamma-gamma prime nickel alloy, nickel-based superalloy, and combinations thereof. 
     
     
         15 . The high temperature die casting system as recited in  claim 1 , wherein the substrate is a superalloy material. 
     
     
         16 . A high temperature die casting system comprising:
 a die casting tool including a substrate and barrier coating on the substrate, wherein the barrier coating is a material selected from a group consisting of partially or fully stabilized zirconia, titanium nitride, tungsten carbide, silicon carbide, silicon nitride, titanium carbide, silicon-aluminum oxy nitride (SiAlON), hafnium carbide, zirconium carbide, and combinations thereof.   
     
     
         17 . The high temperature die casting system as recited in  claim 16 , wherein the barrier coating is a partially or fully stabilized zirconia. 
     
     
         18 . The high temperature die casting system as recited in  claim 16 , wherein the barrier coating is silicon-aluminum-oxy-nitride (SiAlON). 
     
     
         19 . The high temperature die casting system as recited in  claim 16 , wherein the barrier coating is hafnium carbide. 
     
     
         20 . The high temperature die casting system as recited in  claim 16 , wherein the barrier coating is zirconium carbide. 
     
     
         21 . A method for a high temperature die casting system, the method comprising:
 maintaining a die casting tool having dies adapted for forming a component at a temperature above 500° F./260° C.; and   using a barrier coating on at least a portion of the die casting tool that is exposed for contact with molten die casting material to protect an underlying substrate of the die casting tool from the molten die casting material.