Method for manufacturing turbine blade components and turbine blade components using the same

Abstract

To provide a manufacturing method for a turbine blade-shaped component in which an oxidation-resistant coating layer is formed in a hollow cavity such as a cooling passage of a turbine blade-shaped component.SOLUTION: A manufacturing method for a turbine blade-shaped component comprises the steps of: preparing a wax precursor having a shape of a substantially large external shape of a turbine blade-shaped component; forming a shell for casting by surrounding the wax precursor with a refractory-layer coating material; removing the wax precursor from the shell for casting while leaving the refractory-layer coating material; preparing a core having a substantially large cavity shape of the turbine blade-shaped component; forming a core with a composite coating layer made of an oxidation-resistant metal layer and a metal-containing ceramic material layer; sintering an assembled body of the shell for casting and the core with the composite coating layer; performing casting by pouring molten metal of heat-resistant superalloy into a casting mold formed of the core with the composite coating layer and the shell for casting; and transferring the composite coating layer of the oxidation-resistance metal layer and the metal-containing ceramic material layer, from the core with the composite coating layer to the casted heat-resistant superalloy, on an inner surface in a cavity shape of the turbine blade-shaped component.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a turbine airfoil component suitable for use in a heat-resistant superalloy oxidation-resistant coating provided for a gas turbine, and a turbine airfoil component using the same, and particularly relates to a method for manufacturing a turbine airfoil component suitable for use in an oxidation-resistant multilayer coating for a cast alloy by a lost wax method, and a turbine airfoil component using the same.

Background Art

[0002] Turbine airfoil components are used as turbine blades such as in jet engines and gas turbines, and for example, Ni-based superalloys and Co-based superalloys are used. In recent years, in order to improve the efficiency of turbine engines, it is required to increase the turbine inlet temperature. Therefore, it is necessary to improve the high-temperature properties (such as creep properties and oxidation resistance) of Ni-based superalloys. On the surface of Ni-based superalloys, oxidation-resistant and corrosion-resistant coating layers such as Al, Cr, Ni-Al, Pt-Al, and MCrAlY are formed, and in order to prevent the oxidation-resistant and corrosion-resistant coating layers from diffusing into the Ni-based superalloys, it has been proposed to provide a diffusion barrier coating (see Patent Document 1). In addition, it has been proposed to provide an oxidation-resistant bond coat layer having a composition in a thermodynamically equilibrium state with the Ni-based superalloy between the surface of the Ni-based superalloy and the ceramic top coat on the outermost surface of the substrate (see Patent Document 2).

[0003] In addition, since a high-temperature combustion gas close to the melting temperature of the Ni-based superalloy acts on the turbine inlet in the turbine airfoil component, even a material with a high heat-resistant temperature such as a Ni-based superalloy has cooling passages formed inside the turbine airfoil component. In order to manufacture such a turbine airfoil component with a complex shape, it is manufactured through procedures of mold shaping, melting and casting, and solidification control by the lost wax precision casting method (investment casting method) (see Non-Patent Documents 1 and 2). The oxidation-resistant and corrosion-resistant coating layer is applied to the outer surface of the turbine blade components, but conventionally, this coating layer has not been applied to the cooling passages formed inside the turbine blade components.

[0004] On the other hand, the casting method, in which different materials or components are placed in a mold and molten metal is poured in to integrate them with the casting, is widely used for aluminum castings and other applications. Furthermore, a method for applying an oxidation-resistant or abrasion-resistant coating of ceramics or high-melting-point metals to a heat-resistant alloy using a casting method has also been disclosed for forming such coatings on the outer surface of turbine blade components (Patent Document 3). [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] US6830827B2 (Japanese Patent Publication No. 2001-323332) [Patent Document 2] WO2008 / 032806 [Patent Document 3] US6616410B2 [Non-patent literature]

[0006] [Non-Patent Document 1] Lost-Wax Precision Casting Method (edited by the Japan Foundry Association, published by Sangyo Tosho, 2015): Forming Method (pp. 9-78), Melting and Casting (pp. 78-82), and Solidification Control (pp. 85-90) [Non-Patent Document 2] “The Superalloys Fundamentals and Applications” (Roger C. Reedcho, Cambridge University Press, 2006) “3.1 Processing of turbine blading by Solidification Processing” (pp. 122-147) [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] However, with the recent rise in gas turbine temperatures, there have been reports of cooling passages inside components such as gas turbine blades being exposed to high temperatures and suffering oxidative damage. Therefore, if an oxidation-resistant and corrosion-resistant coating layer can be provided inside the components, it would contribute to improving the reliability of gas turbine blades. On the other hand, even with metals that have a high melting point, in castings where the casting temperature exceeds 1500°C, such as with heat-resistant alloys, there is a problem that the metal applied to the mold diffuses into the casting during casting and does not remain on the casting surface. Furthermore, in order to provide an oxidation-resistant and corrosion-resistant coating layer in cavities such as the cooling passages of turbine blade components, it is necessary to apply the corrosion-resistant coating layer to the cooling passages formed inside the complexly shaped gas turbine blades, and there is a problem that it is extremely difficult to provide a corrosion-resistant coating layer of stable quality in the cooling passages of turbine blade components at a practical cost.

[0008] The present invention aims to solve these problems and to provide a method for manufacturing turbine blade components that, when it is necessary to provide an oxidation-resistant coating layer in cavities such as cooling passages in turbine blade components, can be formed using a casting method, and even at high casting temperatures, the high-melting-point metal or alloy used as the oxidation-resistant coating can be formed without diffusion into the interior of the casting. [Means for solving the problem]

[0009] [1] The present invention relates to a method for manufacturing a turbine airfoil component, as shown in Figures 2 and 3, for example, a method for casting a turbine airfoil component having a cavity used in a gas turbine engine or a jet engine, comprising the steps of: producing or preparing a wax precursor 110 having the general shape of the turbine airfoil component (S300); forming a casting shell 120 by wrapping the wax precursor 100 with a refractory layer coating material (ZrO2) (S305); and dewaxing the casting shell 120, leaving the refractory layer coating material and removing the wax precursor 110 (S310). The steps are: (S320) to manufacture or prepare a core having a roughly hollow shape for the turbine blade component; (S325) to form a core 100 with a composite coating layer by coating the surface of the core with an oxidation-resistant metal layer 102a and further coating the surface of the oxidation-resistant metal layer with a metal-containing ceramic material layer 102b; (S330) to sinter the assembly of the casting shell 120 that has undergone the dewaxing step and the core 100 with the composite coating layer; and (S330) to completely dissolve or destroy the refractory coating material and the metal-containing ceramic material layer. Without doing so, the method includes the steps of casting a heat-resistant superalloy into a mold formed of a core 100 with a composite coating layer and a casting shell 120 (S340), transferring a composite coating layer of an oxidation-resistant metal layer 102a and a metal-containing ceramic material layer 102b from the core 100 with the composite coating layer to the cast heat-resistant superalloy on the inner surface of the cavity shape of the turbine blade part (S350), and removing the mold to obtain the turbine blade part made of the cast heat-resistant superalloy and having the cavity shape (S360).

[0010] [2] In the method for manufacturing turbine airfoil components of the present invention [1], preferably the method includes a step (S370) of applying a metal-containing ceramic material layer (diffusion barrier layer) to the surface of the external shape of the turbine airfoil component after casting, and further applying an oxidation-resistant metal layer (oxidation-resistant layer) as a topcoat. [3] The present invention relates to a method for manufacturing a turbine airfoil component, as shown in Figures 4 and 5, for example, a method for casting a turbine airfoil component having a cavity used in a gas turbine engine or a jet engine, comprising the steps of: producing or preparing a wax precursor 110 having the general external shape of the turbine airfoil component (S500); wrapping the wax precursor 110 with a refractory layer coating material (ZrO2), coating the inner surface corresponding to the external shape of the turbine airfoil component with an oxidation-resistant metal layer 112a, and further coating the surface of the oxidation-resistant metal layer 112a with a metal-containing ceramic material layer 112b to form a coated casting shell 120 (S505); and dewaxing the coated casting shell 120, leaving the refractory layer coating material and removing the wax precursor 110 (S510). The steps include (S520) manufacturing or preparing a core having a roughly hollow shape for the turbine blade component, and (S525) coating the surface of the core with an oxidation-resistant metal layer 102a, and further coating the surface of the oxidation-resistant metal layer with a metal-containing ceramic material layer 102b to form a core 100 with a composite coating layer, The steps include: sintering the assembly of the casting shell 120 that has undergone the dewaxing step and the core 100 with a composite coating layer (S530); The process involves (S540) injecting molten heat-resistant superalloy into a mold formed from a core with the composite coating layer and a casting shell 120, without completely dissolving or destroying the refractory coating material and the composite coating layer of the metal-containing ceramic material layer and the oxidation-resistant metal layer, A composite coating layer of oxidation-resistant metal layer 102a and metal-containing ceramic material layer 102b is transferred from the core 100 with the composite coating layer to the cast heat-resistant superalloy (S550), and a composite coating layer of oxidation-resistant metal layer 112a and metal-containing ceramic material layer 112b is transferred from the casting shell 120 to the cast heat-resistant superalloy (S555), on the inner surface of the outer shape of the turbine blade part. The process includes the step (S560) of removing the mold to obtain the turbine blade-shaped component which is made of the cast heat-resistant superalloy and has the hollow shape.

[0011] [4] In the methods for manufacturing turbine airfoil components of the present invention [1] to [3], it is preferable that when coating the surface of the core with the metal-containing ceramic material layer 102b, at least one of the metal-containing ceramic material layer (Al2O3) or the oxidation-resistant metal layer is applied by paste coating. [5] In the methods for manufacturing turbine airfoil components of the present invention [1] to [4], preferably, the heat-resistant superalloy is a Ni-based or Co-based superalloy, the oxidation-resistant metal layer is a high-melting-point metal layer with Pt as the main element, or a high-melting-point alloy layer selected from PtIr or NiAl, and the metal-containing ceramic material layer is a layer containing 0 to 50% by weight of an oxidation-resistant alloy in Al2O3. [6] In the method for manufacturing turbine airfoil components of the present invention [5], the oxidation-resistant alloy is preferably Pt, an alloy with Pt as the main element, PtIr, or NiAl. [7] In the method for manufacturing turbine airfoil components of the present invention [5] or [6], preferably, the oxidation-resistant metal layer is an alloy with Pt as the main element, and the metal-containing ceramic material layer has Al2O3 as its main component. Here, the alloy with Pt as the main element in the oxidation-resistant metal layer means one containing 50% by mass or more of Pt, preferably 80% by mass or more, and more preferably 90% by mass or more. The metal-containing ceramic material layer having Al2O3 as its main component means one containing 50% by mass or more of Al2O3, preferably 70% by mass or more, and more preferably 90% by mass or more. [8] In the method for manufacturing turbine airfoil components of the present invention [7], preferably, the thickness of the oxidation-resistant metal layer is 20 μm or less of Pt, and the thickness of the metal-containing ceramic material layer (diffusion barrier layer) is 20 μm or less of Al2O3.

[0012] [9] The present invention relates to a turbine blade component having a cavity, used in a gas turbine engine or jet engine formed by casting, An oxidation-resistant film structure comprising a predetermined-shaped metal-containing ceramic material layer 102b and an oxidation-resistant metal layer 102a fixedly held on the inner surface of the cavity of the turbine blade-shaped component, A heat-resistant superalloy adjacent to the metal-containing ceramic material layer 102b, The turbine blade-shaped component comprises an outer surface shape and a surface, During casting, the metal-containing ceramic material layer 102b does not come into contact with the metal-containing ceramic material layer 102b, flow, and solidify during cooling from the molten state, thus preventing decomposition of the metal-containing ceramic material layer 102b and the oxidation-resistant metal layer 102a.

[10] The present invention relates to a turbine blade component having a cavity, used in a gas turbine engine or jet engine formed by casting, A first composite coating structure of a first metal-containing ceramic material layer 102b and a first oxidation-resistant metal layer 102a having a predetermined shape, which is fixedly held on the inner surface of the cavity shape of the turbine airfoil component; A second composite coating structure of a second metal-containing ceramic material layer 112b and a second oxidation-resistant metal layer 112a having a predetermined shape, which is fixedly held on the surface of the outer shape of the turbine airfoil component; A heat-resistant superalloy having a first surface adjacent to the first metal-containing ceramic material layer 102b of the first oxidation-resistant film structure and a second surface adjacent to the second metal-containing ceramic material layer 112b of the second oxidation-resistant film structure; During casting, upon cooling from the molten state, it flows and solidifies in contact with the first and second metal-containing ceramic material layers (102b, 112b), and does not cause decomposition of the first and second metal-containing ceramic material layers (102b, 112b) and the first and second oxidation-resistant metal layers (102a, 112a).

Advantages of the Invention

[0013] According to the method for manufacturing a turbine airfoil component of the present invention, by combining the coating on the inner surface of the cavity shape of the turbine airfoil component using a core with the advantages of the investment casting method in the casting of a turbine airfoil component by the lost wax precision casting method, an oxidation-resistant composite coating layer can be formed on the cooling passage of the gas turbine rotor blade, and oxidation damage in the cooling passage can be prevented. Also, if the investment casting method is directly applied, an oxidation-resistant coating layer that disappears due to diffusion into the casting during casting can be left on the surface by providing a diffusion barrier layer, and an oxidation-resistant multilayer coating for a heat-resistant alloy maintaining the oxidation-resistant function can be transferred to the casting surface.

[0014] According to the method for manufacturing a turbine airfoil component [4] of the present invention, by using a paste coating, it becomes possible to simply and inexpensively apply a two-layer coating using a metal-containing ceramic material layer (Al2O3) and an oxidation-resistant metal layer.

[0015] According to the manufacturing method for turbine blade components of the present invention [5], by applying it to Ni-based or Co-based superalloys used in gas turbines, the performance of the oxidation-resistant multilayer coating for heat-resistant alloys that can withstand high casting temperatures can be maximized. According to the method for manufacturing turbine airfoil components of the present invention [5], by providing a diffusion barrier layer of Al2O3-X wt%Pt (X=50~0) beneath an oxidation-resistant coating layer having a high melting point and oxidation resistance, such as Pt or NiAl, the diffusion of metal elements into the casting during casting can be prevented.

[0016] According to the method for manufacturing turbine airfoil components of the present invention [7], the diffusion of Pt as an oxidation-resistant layer into the casting can be effectively prevented by the Al2O3 barrier layer, enabling casting at longer times and higher temperatures, such as unidirectional solidification. According to the manufacturing method of turbine airfoil components of the present invention [8], by setting the thickness of the Pt layer to 20 μm or less and the thickness of the Al2O3 layer to 20 μm or less, it is possible to withstand thermal shock during heating and cooling and improve oxidation resistance in a gas turbine environment where heating and cooling are repeated. [Brief explanation of the drawing]

[0017] [Figure 1] This diagram illustrates the components used in the manufacturing method of the turbine airfoil component of the present invention, where (A) is a ceramic core, (B) is an external view of a turbine blade, and (C) is a cross-sectional view showing a cooling passage formed inside the turbine blade. [Figure 2] This diagram illustrates a first method for manufacturing a turbine airfoil component of the present invention, using a ceramic core and a casting shell for the turbine blade body. [Figure 3] This is a flowchart showing the first method for manufacturing a turbine blade component of the present invention. [Figure 4] This is an explanatory diagram illustrating a second method for manufacturing turbine blade components of the present invention, using a ceramic core and a casting shell for the turbine blade body. [Figure 5] This is a flowchart showing a second method for manufacturing a turbine blade component according to the present invention. [Figure 6A]Figure 4 shows the process of manufacturing a single crystal test specimen using the turbine blade manufacturing method shown, where (A) is mold creation, (B) is wax injection molding, (C) is wax precursor extraction, (D) is composite coating layer application and drying, (E) is mold creation, and (F) is dewaxing. [Figure 6B] Figure 4 shows the process of manufacturing a single crystal test specimen using the turbine blade manufacturing method shown in Figure 4, where (G) shows the mold debindering and firing process, (H) shows casting, and (I) shows the removal of the single crystal test specimen which is the casting. [Figure 7A] This diagram illustrates the details of the composite coating layer of an oxidation-resistant metal layer and a metal-containing ceramic material layer in a single-crystal specimen, with (A) being an explanatory diagram of single-crystal specimen manufacturing by unidirectional solidification. [Figure 7B] This figure illustrates the details of the composite coating layer of an oxidation-resistant metal layer and a metal-containing ceramic material layer in a single-crystal specimen. (B) is an optical photograph of the composite coating layer, and (C) shows the distribution of the composition ratio of the constituent elements from the surface to the thickness direction. [Figure 8] Figure 7 shows an SEM image of a single-crystal specimen from the surface in the thickness direction. [Figure 9] This figure shows a method for manufacturing a unidirectional solidification test specimen using a core. [Figure 10A] This diagram shows the microstructure after casting molten Ni-10 atomic% into a two-layer coating applied to an Al2O3 tube. The Pt layer is a Pt-40 wt% Al2O3 layer (holding time 7 minutes). The upper panel shows a cross-sectional image of the microstructure taken with an SEM, and the lower panel shows the elemental analysis results taken with EDS. [Figure 10B] The structure consists of a Pt-Ir layer and a Pt-40 wt% Al2O3 layer (retention time 7 minutes). The upper panel shows a cross-sectional image of the tissue taken with an SEM, and the lower panel shows the elemental analysis results taken with an EDS. [Figure 11A] The structure consists of a Pt layer and a Pt-70 wt% Al2O3 layer (retention time 7 minutes). The upper panel shows a cross-sectional image of the tissue taken with an SEM, and the lower panel shows the elemental analysis results taken with an EDS. [Figure 11B]The sample consists of a Pt-Ir layer and a Pt-70 wt% Al2O3 layer (retention time 13 minutes). The upper panel shows a cross-sectional image of the tissue taken with an SEM, and the lower panel shows the results of elemental analysis using EDS. [Figure 12A] This is a Pt layer / Al2O3 layer (retention time 7 minutes). The upper panel shows a cross-sectional image of the tissue taken with SEM, and the lower panel shows the elemental analysis results taken with EDS. [Figure 12B] This is a Pt-Ir layer / Al2O3 layer (retention time 26 minutes). The upper panel shows a cross-sectional image of the tissue taken with SEM, and the lower panel shows the elemental analysis results taken with EDS. [Figure 13A] This figure shows the microstructure of a two-layer coating transferred from the inner wall of a mold to a Ni atom % Al casting. The coating consists of a Pt layer and a Pt-70 wt% Al2O3 layer (holding time 5 minutes). The upper panel shows a cross-sectional image of the microstructure taken with an SEM, and the lower panel shows the elemental analysis results taken with an EDS. [Figure 13B] The structure consists of a Pt layer / Al2O3 layer / Al2O3 layer (retention time 5 minutes). The upper panel shows a cross-sectional image of the tissue taken with an SEM, and the lower panel shows the elemental analysis results taken with an EDS. [Figure 14A] This figure shows a cross-section of Ni-10 atom % Al alloy after thermal cycling oxidation test, with a two-layer coating transferred to the surface. The alloy consists of a Pt layer / Pt-70 wt% Al2O3 layer / Ni-10 atom % Al alloy. The upper panel shows a cross-sectional image of the microstructure taken with an SEM, and the lower panel shows the elemental analysis results taken with an EDS. [Figure 14B] This is a Pt layer / Al2O3 layer / Ni-10 atom%Al alloy. The upper panel shows a cross-sectional image of the microstructure taken with SEM, and the lower panel shows the elemental analysis results taken with EDS. [Modes for carrying out the invention]

[0018] The following examples illustrate nickel-cobalt alloys and turbine airfoil members made of nickel-cobalt alloys in more detail. Of course, the present invention is not limited to the following examples. Figure 1 is an explanatory diagram of the components used in the manufacturing method of the turbine airfoil component of the present invention, where (A) is the ceramic core, (B) is an external view of the turbine blade, and (C) is a cross-sectional view showing the cooling passage formed inside the turbine blade. The ceramic core has a negative shape for the cooling passage formed inside the turbine blade. The turbine blade has the outer shape of a single turbine blade in a gas turbine engine or jet engine, as shown in Figure 1(B). The cooling passage formed inside the turbine blade has a positive shape for the cooling passage, as shown in Figure 1(C).

[0019] Figure 2 is an explanatory diagram showing the first manufacturing method of the turbine airfoil component of the present invention, using a ceramic core and a casting shell for the turbine blade body, where (A) is the ceramic core, (B) is the assembled state of the casting shell and ceramic core, (C) is the state in which the oxidation-resistant metal layer and metal-containing ceramic material layer coatings of the ceramic core are transferred to the cast heat-resistant superalloy as the molten metal solidifies, and (D) shows the coating state of the oxidation-resistant metal layer and metal-containing ceramic material layer of the cast turbine airfoil component. Figure 2 is intended to illustrate the technical concept of the present invention, and the dimensions in the drawing do not precisely match those of turbine blade members actually manufactured. Furthermore, to illustrate the oxidation-resistant metal layer and the metal-containing ceramic material coating layer of the ceramic core, parts of the casting shell, turbine blade component, and ceramic core are shown broken.

[0020] The ceramic core 100 has roughly the negative shape of the cooling passage formed inside the turbine blade, and is coated with a composite coating layer of oxidation-resistant metal layer 102a and metal-containing ceramic material layer 102b. The casting shell 120 has roughly the negative shape of the turbine blade component, and is manufactured according to the usual lost-wax precision casting method, in which a wax precursor (wax mold) is formed from a mold, sand called stucco is sprinkled around the wax precursor, drying and slurry dipping are repeated, and then it is fired after dewaxing treatment.

[0021] The assembled state of the casting shell 120 and ceramic core 100 shown in Figure 2(B) is also called a mold. As shown in Figure 2(C), when molten metal is poured into the mold, the composite coating layer of oxidation-resistant metal layer 102a and metal-containing ceramic material layer 102b is transferred from the ceramic core 100 to the solidified cast heat-resistant superalloy 140.

[0022] As shown in Figure 2(D), a composite coating layer of oxidation-resistant metal layer 102a and metal-containing ceramic material layer 102b is transferred to the cast turbine airfoil component 140 in any of the following processes: unidirectional solidification casting, single-crystal casting, or conventional casting. The casting process conditions are defined so that the composite coating layer of oxidation-resistant metal layer 102a and metal-containing ceramic material layer 102b does not diffuse into the cast heat-resistant superalloy substrate and disappear during the unidirectional solidification or single-crystal casting process.

[0023] Figure 3 is a flowchart showing the first method for manufacturing a turbine airfoil component of the present invention. The first method for manufacturing a turbine airfoil component is a method for casting a turbine airfoil component having a cavity for use in a gas turbine engine or jet engine, and involves forming a diffusion barrier layer and oxidation-resistant layer on the core, followed by further forming a diffusion barrier layer and oxidation-resistant layer on the cast body.

[0024] First, as preparation for casting the main body of the turbine blade component, a wax precursor 110 having the approximate outer shape of the turbine blade component is produced (S300). In lost-wax precision casting, in order to obtain the shape of the turbine blade component after casting, it is necessary to determine the shape of the wax precursor 110 taking into account thermal shrinkage due to the temperature difference between room temperature and the molten metal. Therefore, the reason for specifying "wax precursor 110 having the approximate outer shape of the turbine blade component" is that the shape of the wax precursor 110 is determined with the goal of obtaining the outer shape of the turbine blade component after casting.

[0025] Next, the wax precursor 100 is wrapped with a refractory coating material to form a casting shell 120 (S305), and the wax precursor 110 is removed from the casting shell 120 by a dewaxing treatment, leaving the refractory coating material (S310). The refractory coating material is, for example, ZrO2, but other molding materials used for stucco in lost-wax precision casting may also be used. Next, as preparation for casting the core, a core having a roughly hollow shape for the turbine blade component is manufactured or prepared (S320). In lost-wax precision casting, in order to obtain the shape of the turbine blade component after casting, it is necessary to determine the shape of the core taking into account thermal shrinkage due to the temperature difference between room temperature and the molten metal. Therefore, the reason for specifying "a core having a roughly hollow shape for the turbine blade component" is that the shape of the core is determined with the goal of obtaining the outer shape of the turbine blade component after casting.

[0026] Next, the oxidation-resistant metal layer 102a is coated onto the surface of the core, and the surface of the oxidation-resistant metal layer is further coated with a metal-containing ceramic material layer 102b to form a core 100 with a composite coating layer (S325). The material used for the oxidation-resistant metal layer 102a is typically a platinum-based metal element such as Pt-Ir (iridium), but is not limited to this, and may be other oxidation-resistant alloys (Pt, NiAl, etc.). The material used for the metal-containing ceramic material layer 102b is typically (Al2O3-(Pt,Ir)), but any material that forms a barrier layer that prevents the oxidation-resistant metal layer 102a from diffusing and disappearing into the cast turbine airfoil component 140 during the casting process, whether in unidirectional solidification casting, single crystal casting, or ordinary casting, is acceptable. The material used for the metal-containing ceramic material layer 102b may be a layer containing 0 to 50% by weight of an oxidation-resistant alloy (Pt, PtIr, NiAl, etc.) in Al2O3.

[0027] Next, in order to prepare the mold, the assembly of the casting shell 120, which has undergone a dewaxing step, and the core 100 with a composite coating layer is sintered (S330). Without completely melting or destroying the refractory coating material and the metal-containing ceramic material layer, the heat-resistant superalloy is cast using the mold formed from the core 100 with the composite coating layer and the casting shell 120 (S340). As a result, the oxidation-resistant metal layer 102a and the metal-containing ceramic material layer 102b are transferred from the core 100 with the composite coating layer to the cast heat-resistant superalloy on the inner surface of the cavity shape of the turbine blade part (S350). Finally, the mold is removed to obtain a turbine blade part made of cast heat-resistant superalloy and having a cavity shape (S360).

[0028] Next, a metal-containing ceramic material layer (diffusion barrier layer) is applied to the surface of the cast outer shape of the turbine airfoil component, and then an oxidation-resistant metal layer (oxidation-resistant layer) is applied as a topcoat (S370). After this, the single crystal test piece cast from this turbine airfoil component in accordance with the turbine blade manufacturing standards is subjected to appropriate heat treatment, such as solution treatment or aging treatment.

[0029] Figure 4 is an explanatory diagram of the second manufacturing method for turbine airfoil components of the present invention, using a ceramic core and a casting shell for the turbine blade body, where (A) is the wax precursor (wax mold), (B) is the ceramic core, (C) is the assembled state of the casting shell and ceramic core, (D) is the state in which the oxidation-resistant metal layer and metal-containing ceramic material layer coatings of the ceramic core are transferred to the cast heat-resistant superalloy as the molten metal solidifies, and (E) shows the coating state of the oxidation-resistant metal layer and metal-containing ceramic material layer of the cast turbine airfoil component. Figure 4 is intended to illustrate the technical concept of the present invention, and the dimensions in the drawing do not precisely match those of turbine blade members actually manufactured. Furthermore, to illustrate the oxidation-resistant metal layer and metal-containing ceramic material coating layer of the ceramic core, wax precursor, and casting shell, parts of the wax precursor, casting shell, turbine blade component, and ceramic core are shown in a cutaway manner.

[0030] The ceramic core 100 has a roughly negative shape for the cooling passage formed inside the turbine blade, and is coated with a composite coating layer consisting of an oxidation-resistant metal layer 102a and a metal-containing ceramic material layer 102b. The wax precursor (wax mold) 110 is formed from a mold according to the usual procedures of lost-wax precision casting. The wax precursor 110 is coated with a composite coating layer consisting of an oxidation-resistant metal layer 112a and a metal-containing ceramic material layer 112b. The casting shell 120 has the shape of a negative mold of a turbine blade component and is manufactured by repeatedly sprinkling sand called stucco around the wax precursor 110, drying, and dipping in slurry, followed by a dewaxing process and firing. The composite coating layer of oxidation-resistant metal layer 112a and metal-containing ceramic material layer 112b that was present on the wax precursor 110 is transferred to the casting shell 120.

[0031] In any of the casting processes—unidirectional solidification, single-crystal casting, or polycrystalline casting—a composite coating layer of oxidation-resistant metal layers 102a, 112a and metal-containing ceramic material layers 102b, 112b is transferred to the cast turbine airfoil component 140. The casting process conditions are defined so that the composite coating layer of oxidation-resistant metal layers 102a, 112a and metal-containing ceramic material layers 102b, 112b does not diffuse into the cast heat-resistant superalloy substrate and disappear during the unidirectional solidification or single-crystal casting process.

[0032] The assembled state of the casting shell 120 and ceramic core 100 shown in Figure 4(C) is also called a mold. As shown in Figure 4(D), when molten metal is poured into the mold, the composite coating layer of oxidation-resistant metal layer 102a and metal-containing ceramic material layer 102b is transferred from the ceramic core 100 to the solidifying cast heat-resistant superalloy 140. Also, when molten metal is poured into the mold, the composite coating layer of oxidation-resistant metal layer 112a and metal-containing ceramic material layer 112b is transferred from the casting shell 120 to the solidifying cast heat-resistant superalloy 140. As shown in Figure 4(E), in any of the processes of unidirectional solidification, single-crystal casting, and polycrystalline casting, the composite coating layer of oxidation-resistant metal layers 102a, 112a and metal-containing ceramic material layers 102b, 112b is transferred from the core 100 with the composite coating layer and the coated casting shell 120 to the cast turbine airfoil component 140.

[0033] Figure 5 is a flowchart showing a second method for manufacturing a turbine airfoil component according to the present invention. The second method for manufacturing a turbine airfoil component is a method for casting a turbine airfoil component having a cavity for use in a gas turbine engine or jet engine, and involves the simultaneous formation of a diffusion barrier layer and an oxidation-resistant layer between the core and the cast body. First, as preparation for casting the main body of the turbine blade component, a wax precursor 110 having the approximate outer shape of the turbine blade component is prepared (S500). The wax precursor 110 is then covered with a refractory layer coating material (ZrO2), and the inner surface corresponding to the outer shape of the turbine blade component is coated with an oxidation-resistant metal layer 112a. Furthermore, the surface of the oxidation-resistant metal layer 112a is coated with a metal-containing ceramic material layer 112b to form a coated casting shell 120 (S505). Then, in the dewaxing step, the wax precursor 110 is removed from the coated casting shell 120, leaving the refractory layer coating material (S510). Next, as preparation for casting the core, a core having a roughly hollow shape for the turbine blade component is manufactured or prepared (S520), an oxidation-resistant metal layer 102a is applied to the surface of the core 100, and the surface of the oxidation-resistant metal layer is further covered with a metal-containing ceramic material layer 102b to form a core 100 with a composite coating layer (S525).

[0034] Next, in order to prepare the mold, the assembly of the casting shell 120 that has undergone the dewaxing step and the core with the composite coating layer is sintered (S530). Next, without completely dissolving or destroying the refractory layer coating material and the composite coating layer of the metal-containing ceramic material layer and the oxidation-resistant metal layer, molten heat-resistant superalloy is poured into the mold formed by the composite coating layer core and the casting shell 120 to cast (S540). As a result, the composite coating layer of the oxidation-resistant metal layer 102a and the metal-containing ceramic material layer 102b is transferred from the composite coating layer core 100 to the cast heat-resistant superalloy on the inner surface of the cavity shape of the turbine blade part (S550), and the composite coating layer of the oxidation-resistant metal layer 112a and the metal-containing ceramic material layer 112b is transferred from the casting shell 120 to the cast heat-resistant superalloy on the inner surface of the outer shape of the turbine blade part (S555). Finally, the mold is removed to obtain a turbine blade part made of cast heat-resistant superalloy and having a cavity shape (S560). Next, the single-crystal test specimens cast according to the turbine blade manufacturing standards are subjected to appropriate heat treatments, such as solution treatment or aging treatment, on these turbine airfoil components.

[0035] Figures 6A and 6B show the process of manufacturing a single crystal test specimen using the turbine blade body manufacturing method shown in Figure 4. In Figure 6A, (A) is mold creation, (B) is wax injection molding, (C) is wax precursor removal, (D) is composite coating layer application and drying, (E) is mold creation, and (F) is dewaxing. In Figure 6B, (G) is binder removal and firing of the mold, (H) is casting, and (I) is removal of the single crystal test specimen which is the casting.

[0036] Figure 6(A) shows the creation of a mold 10 for a single crystal test specimen. The mold 10 consists of an upper mold 12 and a lower mold 14, and the build space 16 located between the upper mold 12 and the lower mold 14 serves as the female mold for the single crystal test specimen to be cast. The build space 16 is provided with a lower gripping section 22, an upper gripping section 24, a tensile test target section 26, and a selector section 28, corresponding to the shape of the single crystal test specimen to be cast. The tensile test target section 26 is a round bar located between the lower gripping section 22 and the upper gripping section 24, and has a straight length and inner diameter according to the specifications of the tensile test. The selector section 28 is used for solidification control such as single crystal casting of nickel-based superalloys and unidirectional solidification.

[0037] Figure 6(B) shows wax injection molding. Wax 29 is injected into the molding space 16 of the mold 10. Figure 6(C) shows the removal of the wax precursor. Once the wax 29 solidifies, the mold 10 is removed and the wax precursor 30 of the single crystal test specimen is extracted. The wax precursor 30 is provided with a lower gripping section 32, an upper gripping section 34, a tensile test target section 36, and a selector section 38, corresponding to the build space 16.

[0038] Figure 6(D) shows the application and drying of the composite coating layer to the wax precursor 30. A metal-containing ceramic material layer 37b is applied to the tensile test target portion 36 of the wax precursor 30, and the surface of the metal-containing ceramic material layer 37b is further coated with an oxidation-resistant metal layer 37a to form the coated wax precursor 30.

[0039] Figure 6(E) shows the mold creation process. In mold creation, a casting shell 40 is manufactured by repeatedly sprinkling sand called stucco onto a coated wax precursor 30 using the lost-wax precision casting method, followed by drying and slurry immersion. Figure 6(F) shows the dewaxing treatment of the casting shell 40. The dewaxing treatment removes the wax precursor 30 from the casting shell 40. At this time, a composite coating layer of metal-containing ceramic material layer 47b and oxidation-resistant metal layer 47a is transferred to the inner surface of the casting shell 40 corresponding to the tensile test target area 36.

[0040] Figure 6(G) shows the binder removal and firing processes of the mold. The casting shell 40, which serves as the mold, is provided with a molding space 41 having a female mold for the single crystal test piece to be cast. Figure 6(H) shows the casting process. For nickel-based superalloys, a vacuum high-frequency induction melting furnace is used for solidification control in single-crystal casting, unidirectional solidification, and conventional casting. Zirconia or alumina is used for the lining of the vacuum high-frequency induction melting furnace. The casting temperature is +90 to 170°C above the solidification start temperature of the casting alloy, and the mold preheating temperature is 1000 to 1100°C for conventional casting and 1400 to 1550°C for single-crystal casting and unidirectional solidification. Figure 6(I) shows the removal of a single-crystal test specimen, which is a casting. The single-crystal test specimen 50 is provided with a lower gripping portion 52, an upper gripping portion 54, and a tensile test target portion 56. The tensile test target portion 56 is provided with a composite coating layer of an oxidation-resistant metal layer 57a and a metal-containing ceramic material layer 57b. The portion corresponding to the selector portion is necessary for single-crystal casting but is unnecessary for the single-crystal test specimen, so it has been removed. The cast single-crystal test specimen is subjected to appropriate heat treatment, such as solution treatment or aging treatment, according to the turbine blade manufacturing standards. [Examples]

[0041] As shown in Figure 7, the experiment in Example 1 was conducted as a preliminary experiment using a manufacturing process that allows oxidation resistance to be imparted to the cast material in the as-cast state by applying Pt, a material with excellent oxidation resistance, to the surface of a mold made of nickel-based superalloy model TMS138 using a paste method, etc., and transferring the applied layer to the cast material during casting. As a result, the preliminary experiment confirmed that a concentrated layer of elements with excellent oxidation resistance can be obtained on the surface of the cast material by paste coating transfer. Here, the nominal composition of TMS138 is, in mass%, 5.8% Co (cobalt), 3.2% Cr (chromium), 2.8% Mo (molybdenum), 5.9% W (tungsten), 5.9% Al (aluminum), 0.0% Ti (titanium), 5.6% Ta (tantalum), 0.1% Hf (hafnium), 5.0% Re (rhenium), 2.0% Ru (ruthenium), with the remainder being Ni (nickel) and unavoidable impurities.

[0042] Figure 7 illustrates the details of the composite coating layer of an oxidation-resistant metal layer and a metal-containing ceramic material layer in a single-crystal specimen. (A) is an explanatory diagram of the single-crystal specimen manufacturing process by unidirectional solidification, (B) is an optical photograph of the composite coating layer, and (C) shows the distribution of the composition ratio of the constituent elements from the surface to the thickness direction. In the production of single-crystal test specimens using nickel-based superalloys, a vacuum high-frequency induction melting furnace (not shown) is used. The molten nickel-based superalloy is, for example, at 1560-1640°C and is poured into a ceramic mold installed in the vacuum high-frequency induction melting furnace to produce the single-crystal test specimen. The inner surface of the ceramic mold is coated with a composite coating layer consisting of an oxidation-resistant metal layer and a metal-containing ceramic material layer.

[0043] The cross-sectional image of the microstructure in Figure 7(B) was taken with an optical microscope. The surface modification layer in the figure corresponds to a composite coating layer of an oxidation-resistant metal layer and a metal-containing ceramic material layer, and the molten metal solidification area is the region formed by the solidification of molten nickel-based superalloy. The thickness of the surface modification layer is approximately 20 μm, and the region where the surface modification layer and the molten metal solidification area have mutually diffused is located in the region 20-30 μm from the surface. The main body of the molten metal solidification area is located in the region at a depth of more than 30 μm from the surface.

[0044] The elemental composition ratio distribution diagram in Figure 7(C) was measured using an elemental analyzer employing the EDS (Energy Dispersive X-ray spectroscopy) method. In the region from the surface to 20 μm, the composition is 30-40 at% Pt, 30-50 at% Ni, 6-20 at% Al, 2-6 at% Co, and 2-4 at% Cr. In the region from 20-30 μm from the surface, Pt decreases with depth from 40 at% to 4 at%, while Ni increases with depth from 40 at% to 75 at%. At depths greater than 30 μm from the surface, the composition is 75 at% Ni, 6-10 at% Al, 8 at% Co, and 4 at% Cr, but Pt is only 0-1 at%. Figure 8 is a scanning electron microscope (SEM) image of the single-crystal specimen shown in Figure 7, viewed from the surface in the thickness direction. The cross-sectional image of the microstructure in Figure 8 was taken with a scanning electron microscope. [Examples]

[0045] A Pt paste or Pt-20 wt% Ir paste was applied to the surface of an Al2O3 ceramic tube, which mimicked a core, and dried. Then, a powder paste of either Al2O3, Pt-70 wt% Al2O3, or Pt-40 wt% was applied to the Pt paste surface and dried. After that, the applied powder paste was debindered at a medium temperature, and then fired at a high temperature to form a two-layer coating. This coated Al2O3 tube was placed inside a mold and solidified in one direction.

[0046] Figure 9 shows a method for manufacturing a unidirectional solidification test specimen using a core. Ni-10 atomic%Al was used as the model alloy for the superalloy, and the molten metal was cast at a temperature of 1500°C into a mold held at 1500°C. Then, the mold was pulled down at a constant speed to perform unidirectional solidification. Since the sample was cut at different positions to prepare samples for cross-sectional observation, the time from melt to solidification differed, and the time until solidification was defined as the time the coating was in contact with the melt (holding time).

[0047] Figures 10A, 10B, 11A, 11B, 12A, and 12B show the structure and compositional analysis results of each coating layer after solidification. Figures 10A, 10B, 11A, 11B, 12A, and 12B show the microstructure after casting molten Ni-10 atomic% into a two-layer coating applied to an Al2O3 tube. Figure 10A shows the Pt layer / Pt-40 wt% Al2O3 layer (holding time 7 minutes), with the upper panel showing a cross-sectional image of the microstructure taken with an SEM and the lower panel showing the elemental analysis results using the EDS method. In Figures 10A, 11A, and 12A, the elements analyzed were Pt, Ni, Al, and O.

[0048] Figure 10B shows a Pt-Ir layer / Pt-40 wt%Al2O3 layer (retention time 7 minutes). The upper panel shows a cross-sectional image of the tissue taken with an SEM, and the lower panel shows the elemental analysis results using EDS. In Figures 10B, 11B, and 12B, the five elements Pt, Ir, Ni, Al, and O were analyzed. Figure 11A shows a Pt layer / Pt-70 wt%Al2O3 layer (retention time 7 minutes), with the upper panel showing a cross-sectional image of the tissue taken with SEM and the lower panel showing the elemental analysis results using EDS. Figure 11B shows a Pt-Ir layer / Pt-70 wt%Al2O3 layer (retention time 13 minutes), with the upper panel showing a cross-sectional image of the tissue taken with SEM and the lower panel showing the elemental analysis results using EDS. Figure 12A shows a Pt layer / Al2O3 layer (retention time 7 minutes), with the upper panel showing a cross-sectional image of the tissue taken with an SEM and the lower panel showing the elemental analysis results using EDS. Figure 12B shows a Pt-Ir layer / Al2O3 layer (retention time 26 minutes), with the upper panel showing a cross-sectional image of the tissue taken with an SEM and the lower panel showing the elemental analysis results using EDS.

[0049] When Pt-40 wt% Al is used as a diffusion barrier layer (Figures 10A and 10B), outward diffusion of Ni from the cast alloy to the outer layer and inward diffusion of Pt from the outer layer (Pt or Pt-Ir) to the interior of the alloy occur, leaving no Pt in the outer layer. In the Pt-70 wt%Al2O3 layer (Figures 11A and 11B), after 7 minutes of holding, Ni penetration into the barrier layer was observed, but it did not reach the outer Pt layer, and the oxidation-resistant Pt coating remained intact on the surface. However, after 13 minutes, Ni diffusion had penetrated the barrier layer and reached the outer Pt-Ir layer, with the outer layer being replaced by Ni and almost no Pt remaining.

[0050] On the other hand, when Al2O3 is used as a barrier layer (Figures 12A and 12B), no diffusion of Ni and Pt into the barrier layer is observed even in the sample at 26 minutes, where the cutting position is highest. A two-layer coating consisting of an oxidation-resistant layer of Pt or a Pt-Ir alloy and a diffusion barrier layer of Al2O3 is formed on the surface of the Ni-10Al cast alloy. In cases where there is no diffusion barrier layer and high-melting-point metals such as Pt or Ir come into direct contact with the molten Ni-10 atom%Al, rapid dissolution and diffusion into the Ni-10 atom%Al occurs, and no surface enrichment layer of these elements is observed. [Examples]

[0051] To prepare oxidation test specimens, Pt paste was applied to the inner wall of a mold in a unidirectional solidification furnace and dried. Then, Pt-70 wt% Al2O3 paste or Al2O3 paste was applied, followed by binder removal and firing to create a two-layer coating. Oxidation samples were prepared by casting Ni-10 atomic% Al alloy, used as a model alloy, into these two-layer coated molds at 1500°C.

[0052] Figures 13A and 13B show the microstructure of a two-layer coating transferred from the inner wall of the mold to a Ni atom % Al casting. Figure 13A shows a Pt layer / Pt-70 wt% Al2O3 layer (holding time 5 minutes), with the upper panel showing a cross-sectional image of the microstructure taken with an SEM and the lower panel showing the elemental analysis results using EDS. Figure 13B shows a Pt layer / Al2O3 layer / Al2O3 layer (holding time 5 minutes), with the upper panel showing a cross-sectional image of the microstructure taken with an SEM and the lower panel showing the elemental analysis results using EDS. All coatings were transferred intact from the mold to the casting through casting. The oxidation resistance of the coatings was evaluated by repeating a thermal cycle oxidation test 100 times, in which the coating was heated from room temperature to 1150°C in air, oxidized for 1 hour, and then cooled back to room temperature.

[0053] Figures 14A and 14B show cross-sections of Ni-10 atom %Al alloys with a two-layer coating transferred to the surface after thermal cycling oxidation testing. Figure 14A shows a Pt layer / Pt-70 wt%Al2O3 layer / Ni-10 atom %Al alloy, with the upper panel showing a cross-sectional image of the microstructure taken with an SEM and the lower panel showing the elemental analysis results using EDS. Figure 14B shows a Pt layer / Al2O3 layer / Al2O3 layer / Ni-10 atom %Al alloy, with the upper panel showing a cross-sectional image of the microstructure taken with an SEM and the lower panel showing the elemental analysis results using EDS. Although cracks were observed in the Pt / Pt-70 wt%Al2O3 sample, no significant oxidation was observed in either the sample shown in Figure 14A or Figure 14B, confirming its function as an oxidation-resistant coating. These coatings consist of two layers: an oxidation-resistant layer and a diffusion-resistant barrier layer. However, while these two layers form the basic structure, a gradient composition layer may be added to enhance the adhesion between each layer, resulting in a multilayer coating of two or more layers. [Industrial applicability]

[0054] According to the present invention's method for manufacturing turbine airfoil components, by combining the casting of turbine airfoil components by the lost-wax precision casting method with coating the inner surface of the cavity shape of the turbine airfoil component using a core, which takes advantage of the benefits of the casting method, an oxidation-resistant composite coating layer can be formed on the cooling passage of the gas turbine blade, thereby preventing oxidation damage in the cooling passage, and is suitable for use in the manufacture of turbine blades for gas turbines and jet engines. [Explanation of Symbols]

[0055] 10, 12, 14 molds 16 Build space 20. Space for wax precursor (for casting single crystal test pieces) 22, 32, 52 Lower gripping section of the test specimen 24, 34, 54 Upper gripping section of the test specimen 26, 36, 56 Elongation test section 28, 38 Selector section 29 Filling wax 30. Wax precursor (for casting single crystal test pieces) 37a, 47a, 57a Oxidation-resistant metal layer (Pt-Ir) 37b, 47b, 57b Metal-containing ceramic material layer (Al2O3-(Pt,Ir)) 40 Casting shells (for casting single crystal test specimens) 41. Space for molten metal injection (for casting single crystal test specimens) 49 Molten metal 50 Single crystal test pieces (cores) 100 core, core with composite coating layer 110 Wax Precursors 120 Casting Shells 140 Turbine blade components 102a, 112a Oxidation-resistant metal layer (Pt-Ir) 102b, 112b Metal-containing ceramic material layer (Al2O3-(Pt,Ir))

Claims

1. A method for casting a turbine blade component having a cavity for use in a gas turbine engine or a jet engine, The steps include: manufacturing or preparing a wax precursor having the approximate outer shape of the turbine blade component; The steps include: wrapping the wax precursor with a refractory coating material to form a casting shell; A dewaxing step of removing the wax precursor from the casting shell while leaving the refractory layer coating material, The steps include manufacturing or preparing a core having a roughly hollow shape for the turbine blade component, The steps include: coating the surface of the core with an oxidation-resistant metal layer, and further coating the surface of the oxidation-resistant metal layer with an Al₂O₃ layer to form a core with a composite coating layer; The steps include: sintering the assembly of the casting shell that has undergone the dewaxing step and the core with the composite coating layer; A method for manufacturing a turbine blade part, comprising: pouring molten heat-resistant superalloy into a mold formed of a core with the composite coating layer and a casting shell without completely dissolving or destroying the refractory layer coating material and the composite coating layer of the Al₂O₃ layer and the oxidation-resistant metal layer; transferring the composite coating layer of the oxidation-resistant metal layer and the Al₂O₃ layer from the core with the composite coating layer to the cast heat-resistant superalloy on the inner surface of the cavity shape of the turbine blade part; and removing the mold to obtain the turbine blade part made of the cast heat-resistant superalloy and having the cavity shape.

2. A method for manufacturing a turbine blade part according to claim 1, comprising applying an Al₂O₃ layer to the surface of the cast outer shape of the turbine blade part, and further applying an oxidation-resistant metal layer as a topcoat.

3. A method for casting a turbine blade component having a cavity for use in a gas turbine engine or a jet engine, The steps include: manufacturing or preparing a wax precursor having the approximate outer shape of the turbine blade component; The steps include: wrapping the wax precursor with a refractory coating material, coating the inner surface corresponding to the outer shape of the turbine blade component with an oxidation-resistant metal layer, and further coating the surface of the oxidation-resistant metal layer with an Al₂O₃ layer to form a casting shell; A dewaxing step of removing the wax precursor from the casting shell while leaving the refractory layer coating material, The steps include manufacturing or preparing a core having a roughly hollow shape for the turbine blade component, The steps include: coating the surface of the core with an oxidation-resistant metal layer, and further coating the surface of the oxidation-resistant metal layer with an Al₂O₃ layer to form a core with a composite coating layer; The steps include: sintering the assembly of the casting shell that has undergone the dewaxing step and the core with the composite coating layer; A method for manufacturing a turbine blade part, comprising: pouring molten heat-resistant superalloy into a mold formed of a core with the composite coating layer and a casting shell without completely dissolving or destroying the refractory layer coating material and the composite coating layer of the Al₂O₃ layer and the oxidation-resistant metal layer; transferring the composite coating layer of the oxidation-resistant metal layer and the Al₂O₃ layer from the core with the composite coating layer to the cast heat-resistant superalloy on the inner surface of the cavity shape of the turbine blade part; and transferring the composite coating layer of the oxidation-resistant metal layer and the Al₂O₃ layer from the casting shell to the cast heat-resistant superalloy on the inner surface of the outer shape of the turbine blade part; and removing the mold to obtain the turbine blade part made of the cast heat-resistant superalloy and having the cavity shape.

4. A method for manufacturing a turbine blade component according to any one of claims 1 to 3, wherein when coating the surface of the core with the Al₂O₃ layer, at least one of the Al₂O₃ layer or the oxidation-resistant metal layer is applied by paste coating.

5. The heat-resistant superalloy is a Ni-based or Co-based superalloy. The method for manufacturing a turbine blade component according to claim 1, wherein the oxidation-resistant metal layer is a high-melting-point metal layer with Pt as the main element, or a high-melting-point alloy layer selected from PtIr or NiAl.

6. The method for manufacturing a turbine airfoil component according to claim 5, wherein the oxidation-resistant metal layer is Pt, PtIr, or NiAl.

7. The method for manufacturing a turbine blade component according to claim 5, wherein the oxidation-resistant metal layer is an alloy with Pt as the main element.

8. The thickness of the oxidation-resistant metal layer is 20 μm or less. The aforementioned Al ２ O ３ The method for manufacturing a turbine blade component according to claim 7, wherein the thickness of the layer is 20 μm or less.

9. A turbine blade-shaped component having a cavity, used in a gas turbine engine or jet engine formed by casting, An oxidation-resistant film structure comprising a predetermined shape of Al₂O₃ layer and an oxidation-resistant metal layer fixedly held on the inner surface of the cavity of the turbine blade-shaped component, A heat-resistant superalloy adjacent to the aforementioned Al₂O₃ layer, The turbine blade-shaped component comprises an outer surface shape and a surface, A turbine blade-shaped component that, during casting, does not flow and solidify upon contact with the Al₂O₃ layer during cooling from a molten state, thereby preventing decomposition of the Al₂O₃ layer and the oxidation-resistant metal layer.

10. A turbine blade-shaped component having a cavity, used in a gas turbine engine or jet engine formed by casting, A first oxidation-resistant film structure comprising a predetermined shape of Al₂O₃ layer and a first oxidation-resistant metal layer fixedly held on the inner surface of the cavity of the turbine blade-shaped component, A second oxidation-resistant film structure comprising a predetermined shape of Al₂O₃ layer fixedly held on the surface of the outer shape of the turbine blade component and a second oxidation-resistant metal layer, A heat-resistant superalloy having a first surface adjacent to the Al₂O₃ layer of the first oxidation-resistant film structure and a second surface adjacent to the Al₂O₃ layer of the second oxidation-resistant film structure, Equipped with, A turbine blade-shaped component that, during casting, does not flow and solidify upon contact with the Al₂O₃ layer during cooling from a molten state, thereby preventing decomposition of the Al₂O₃ layer and the first and second oxidation-resistant metal layers.

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