Process For Producing A Lost Model, And Core Introduced Therein

Abstract

The invention relates to a method for the production of a pattern for precision casting representation of turbine component comprising at least one cavity, whereby the prepared pattern comprises at least one core and an outer contour pattern, at least partly enclosing the core and at least partly defining the outer contour of the turbine component. The core is made from a hardening core material, which hardens during the course of the method and the outer contour pattern is made from a combustible or fusible material. The outer contour model is first produced with at least one cavity corresponding to the at least one cavity of the turbine component and subsequently, in order to form the at least one care, the hardening core material is introduced into the at least one cavity and hardened.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application is the US National Stage of International Application No. PCT / EP2005 / 055769, filed Nov. 4, 2005 and claims the benefit thereof. The International Application claims the benefits of European application No. 04027895.4 filed Nov. 24, 2004, both of the applications are incorporated by reference herein in their entirety.FIELD OF INVENTION[0002]The present invention relates to a process for producing a model for the production by investment casting of a component that has a cavity, and to a process for producing a casting mold for a component that has at least one cavity, in which a model is used for producing the component by investment casting.BACKGROUND OF THE INVENTION[0003]When producing hollow cast components, such as for example turbine components, the production of the cavity is of particular importance. By way of example, turbine blades or vanes for gas turbines have a main blade or vane part, which has a leading edge...

AI Technical Summary

Benefits of technology

The present invention provides an improved process for producing a model and mold for turbine components that have cavities using a process called investment casting. The process involves producing a model with a core and an external contour model, which simultaneously serves as a casting or injection mold for the core. This eliminates the need for separate tools for the core, reducing costs and development time. The external contour model is produced using a rapid prototype process, such as stereolithography or rapid laser sintering, which makes the process faster and more flexible compared to traditional methods. The process also allows for earlier introduction of new designs to the market and faster reaction to service-related design changes.

Problems solved by technology

The shape and position of the cavity within the main blade or vane part therefore represents a particular challenge in the design of turbine blades and vanes.

Since, despite computer-aided technology used to simulate flow and cooling properties, the core design none the less has to be corrected by means of tests in the final stage of product development, the process described is relatively complex in product development, since new casting or injection molds for the core and wax model have to be produced for each design.

However, even this procedure only allows local corrections but does not permit an overall correction to the core design.

Moreover, in the process described in DE 101 29 975 A1, corrections to the design of the external contour of the turbine blade or vane are not possible without producing new tools, such as for example new casting molds.

The production of tools for the manufacture of the ceramic cores and of the wax models continues to be complex and expensive.

For example, during the production process development for hollow cast turbine blades or vanes, a large proportion of the development time and development costs are attributable to the production of the tools.

Moreover, the tools can only be released for series production once the design of the hollow cast turbine component has been released.

Otherwise, changes to the design can lead to a considerable time delay and high costs.

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