Die cast system for forming a component usable in a gas turbine engine

Abstract

A die cast system having an inner liner insert that enables the configuration of a component produced by the system to be easily changed by changing the inner liner insert without having to rework the die housing is disclosed. Because the inner liner insert only need be removed and replaced to change the configuration of an outer surface of a component produced by the system, the cost savings is significant in contrast with conventional systems in which the die would have to be reworked.

Description

FIELD OF THE INVENTION[0001]This invention is directed generally to die cast systems, and more particularly to manufacturing methods for turbine airfoils usable in turbine engines.BACKGROUND[0002]Turbine blade airfoils typically have internal cooling systems formed from a plurality of cooling channels, as shown in FIGS. 2 and 3. To form these cooling channels inside of a blade, a casting mold is often used and includes an internal ceramic core and external ceramic shell. The ceramic core, as shown in FIG. 1, is manufactured to include detail features on the core die surface in order to form efficient cooling devices inside the blade casting. The core dies typically used to form cores are most often formed from hard steel, which are expensive to manufacture. The core die surfaces are typically in direct contact with the ceramic core material during the high pressure injection process. The core die will wear out after sufficient injections and lead to non-conforming casting. To mainta...

AI Technical Summary

Benefits of technology

The patent describes a die cast system that allows for easy change of the inner liner insert to change the configuration of a component produced by the system. This means that the cost savings is significant when compared with conventional systems that have to rework the die housing. The system also includes an inner liner formed from two sub-inner liners that can create more intricate cooling systems by using different materials that have varying degrees of compliance. The use of the hybrid die cast system reduces time and effort required to create a core die and allows for the formation of intricate aspects of an internal cooling system.

Problems solved by technology

The core dies typically used to form cores are most often formed from hard steel, which are expensive to manufacture.

The core die will wear out after sufficient injections and lead to non-conforming casting.

To maintain accurate casting dimensions, the core die needs to be reworked or replaced when a core die becomes worn, which is an expensive endeavor.

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