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Investment casting utilizing flexible wax pattern tool

A technology of investment casting and flexible mold, which is applied in the field of investment casting and can solve problems such as size increase

Active Publication Date: 2012-11-28
SIEMENS ENERGY INC +1
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

While there have been incremental improvements in the field of investment casting, the inventors have realized that the industry faces a number of fundamental limitations that constrain the design of components in many areas of planned progress, for example in the next generation of gas turbine engines , ignition temperatures continue to increase to improve combustion efficiency, and the size of hot gas path components in gas turbines continues to increase with increasing power levels

Method used

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  • Investment casting utilizing flexible wax pattern tool
  • Investment casting utilizing flexible wax pattern tool
  • Investment casting utilizing flexible wax pattern tool

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Embodiment Construction

[0033] As part of an investment casting process—such as may be used to cast gas turbine blades or other components with complex internal cooling passages—a ceramic core is first fabricated that will define the internal cooling passages. shape. Figure 1 illustrates such a ceramic core 10, which may be formed by any known method.

[0034] After the ceramic core has been produced, the next step in the investment casting process is to use the core as part of a wax pattern tool used to cast wax around the core to define the final outer surface shape of the cast blade or other cast part . Wax pattern tool designs in the prior art are complex and expensive when multiple opening surfaces are required to remove the tool from the wax pattern or other cast part due to part geometry. The present invention provides a new method for wax-up tooling that reduces the time and cost of tooling to a fraction of the time and cost required for traditional wax-up tooling, and provides the ability ...

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Abstract

An investment casting process wherein the wax pattern tool (44) is flexible to facilitate removal of the tool from the cast wax pattern (52) even when the cast shape would otherwise require multiple pull planes. The flexible tool may include a flexible insert (42) precisely indexed to a surrounding coffin mold (40), and thereby to an enclosed ceramic core (10). Positioning pins (106) may extend from the flexible tool to make compliant contact against the core prior to a wax injection step. The surface of the resulting wax pattern may contain an engineered topography (36) replicated through the flexible surface from a master tool (12). The flexible tool may encase thermally conductive or magnetic particles (92), or other active device (96) such as a sensor or vibrator which is operable during wax injection.

Description

[0001] Cross-References to Related Applications [0002] This application claims the benefit of U.S. Provisional Application No. 61 / 267,519 (Attorney Docket 2009P22785US), filed December 8, 2009, which is hereby incorporated by reference in its entirety. technical field [0003] The present invention relates generally to the field of investment casting and, more particularly, to the use of flexible tools or molds to form wax patterns as part of an investment casting process. Background technique [0004] Investment casting is one of the oldest known metal-forming processes, dating back thousands of years to the time it was first used to create detailed crafts from metals such as copper, bronze and gold. Industrial investment casting became common in the 1940s when World War II increased the need for precision-sized parts made of specialized metal alloys. Today, investment casting is commonly used in the aerospace and power industries to manufacture gas turbine components su...

Claims

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Application Information

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IPC IPC(8): B22C7/02B22C9/04B22C9/24
CPCB22C7/02B22C9/04B22C9/10B22C9/24B22C23/00
Inventor 加里·B·梅里尔阿利斯特·W·詹姆斯安德鲁·J·布恩斯凯文·C·希恩本杰明·E·河纳韦尔德伊恩·A·弗雷泽
Owner SIEMENS ENERGY INC
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