Disposable thin wall core die, methods of manufacture thereof and articles manufactured therefrom

Abstract

Disclosed herein is a method comprising injecting into a thin wall disposable core die (100) a slurry having a viscosity of about 1 to about 1,000 Pascal-seconds at room temperature when tested at a shear rate of up to 70 seconds -1 and a flow index of less than 0.6 at a pressure of up to about 7 kilograms-force per square centimeter; wherein the thin wall disposable core die (100) has an average wall thickness of about 1.5 to about 10 millimeters; curing the slurry to form a cured ceramic core; removing the thin wall disposable core die (100) from the cured ceramic core (90); and firing the cured ceramic core to form a solidified ceramic core (90).

Description

technical field [0001] The invention relates to a disposable thin-walled mandrel, its manufacturing method and products manufactured therefrom. Background technique [0002] Casting parts with complex geometries, such as those with internal channels and cavities, is difficult with current commercial methods. The molds used to manufacture these parts are expensive and time-consuming, eg requiring long lead times. The situation described above is exacerbated by the nature of conventional molds, which consist of a shell and one or more separate forming cores, where the cores have a tendency to shift during casting, resulting in low casting tolerances and low Casting efficiency (yield). Examples of components with complex geometries that are difficult to cast conventionally include hollow airfoils for gas turbine engines, and especially relatively small double-walled airfoils. Examples of such airfoils for gas turbine engines include rotor blades and stator blades of the turb...

AI Technical Summary

Problems solved by technology

This metal mandrel is heavy, expensive to produce, and the manufacturing method is usually time consuming

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