System and method for casting using a mold with thermally customized

Abstract

A system having a controller configured to receive a computer model of a mold configured to cast a component is provided. The computer model has a variable wall thickness of the mold that is thermally tailored to the geometry of the component. The controller is configured to control a manufacturing system to produce the mold based on the computer model.

Description

Background Art

[0001] The present application relates generally to a gas turbine system and, more particularly, to a system and method for casting components of a gas turbine system.

[0002] A gas turbine system may include a compressor, a combustor, and a turbine. Various components of a gas turbine system may have complex geometries that are difficult to manufacture through a casting process. For example, a component of a compressor or turbine (e.g., a blade or guide vane) may have a complex geometry in which the thickness or cross-sectional area varies across the component. Unfortunately, complex geometries can cause difficulties during the casting process because thickness variations typically cause changes in the cooling and solidification of the component because the latent heat generated during solidification is proportional to the cross-sectional area of ​​the metal. Typically, large cross-sections or thicker wall locations tend to have slower cooling rates and thermal gradients, which increases the probability of grain defects such as stray crystals, streaky crystals, and freckles forming. A mold with a constant wall thickness will not be able to cope with these thickness variations, resulting in undesirable cooling and solidification of the component during the casting process. Therefore, a mold customized for the complex geometry of the component (particularly thickness variations) is needed to help improve the cooling and solidification of the component during the casting process. Summary of the invention

[0003] Certain embodiments comparable in scope to the originally claimed subject matter are summarized below. These embodiments are not intended to limit the scope of the claimed embodiments, but rather, these embodiments are intended only to provide a brief overview of possible forms of the subject matter. In fact, the presently claimed embodiments may include various forms that may be similar or different from the embodiments set forth below.

[0004] In certain embodiments, a system includes a controller configured to receive a computer model of a mold configured to cast a component, wherein the computer model has a variable wall thickness of the mold thermally customized to a geometry of the component. The controller is configured to control a manufacturing system to produce the mold based on the computer model.

[0005] In certain embodiments, a method includes receiving, by a controller, a computer model of a mold configured to cast a component, wherein the computer model has a variable wall thickness of the mold thermally customized to the geometry of the component. The method also includes controlling, by the controller, a manufacturing system to produce the mold based on the computer model.

[0006] In certain embodiments, a system includes a controller configured to receive a computer model of a mold configured to cast a component, wherein the computer model has a variable wall thickness of the mold thermally customized to a geometry of the component. The controller is configured to control a manufacturing system to produce the mold based on the computer model. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These and other features, aspects and advantages of the presently disclosed technology will be better understood when the following detailed description is read with reference to the accompanying drawings, in which like characters refer to like parts throughout the drawings, and in which:

[0008] Figure 1 is a block diagram of an embodiment of a manufacturing system for casting a component using a mold having a variable wall thickness tailored to the variable thickness of the component.

[0009] Figure 2 is used to pass Figure 1 A perspective view of an embodiment of a mold for a casting component of a manufacturing system.

[0010] Figure 3 yes Figure 1 and Figure 2 A cutaway perspective view of an embodiment of a mold further illustrating the interior details of the mold body.

[0011] Figure 4 is along Figure 2 The line 4-4 is intercepted Figures 1 to 3 A cross-sectional view of an embodiment of a mold showing the variation in wall thickness of the mold.

[0012] Figure 5 is along Figure 2 The line 5-5 is intercepted Figures 1 to 3 A cross-sectional view of an embodiment of a mold showing the variation in wall thickness of the mold.

[0013] Figure 6 is along Figure 2 The line 6-6 is intercepted Figures 1 to 3 A cross-sectional view of an embodiment of a mold showing the variation in wall thickness of the mold.

[0014] Figure 7 is along Figure 2 The line 7-7 is intercepted Figures 1 to 3 A cross-sectional view of an embodiment of a mold showing the variation in wall thickness of the mold.

[0015] Figure 8 is Figure 1 Schematic diagram of an embodiment of a solidification profile (e.g., a concave solidification profile) of a material of a component that transitions from a liquid state to a solid state in a mold during cooling in a casting system.

[0016] Fig. 9 is Figure 1 Schematic diagram of an embodiment of a solidification profile (e.g., a flat solidification profile) of a material of a component that transitions from a liquid state to a solid state in a mold during cooling in a casting system.

[0017] Fig.10 yes Figures 1 to 7 Schematic partial cross-sectional view of an embodiment of a mold, further illustrating thickness variations of the components and the mold body.

[0018] Fig.11 yes Figures 1 to 7 Schematic partial cross-sectional view of an embodiment of a mold, further illustrating thickness variations of the components and the mold body.

[0019] Fig.12 is the component thickness of the component and Figures 1 to 7 A graph of an embodiment of the relationship between the mold thermal resistance of a mold.

[0020] Fig.13 is to use Figures 1 to 7 A flow chart of an embodiment of a process for manufacturing a mold cast component. DETAILED DESCRIPTION

[0021] One or more specific embodiments of the currently disclosed embodiments will be described below. In order to provide a concise description of these embodiments, all features of the actual implementation may not be described in the specification. It should be understood that in the development of any such actual implementation, as in any engineering or design project, many implementation-specific decisions must be made to achieve the developer's specific goals, such as complying with system-related and business-related constraints, which may vary from implementation to implementation. In addition, it should be understood that such development work may be complex and time-consuming, but it is still a routine task of design, production and manufacturing for ordinary technicians who benefit from this disclosure.

[0022] When introducing elements of various embodiments of the presently disclosed embodiments, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of the elements. The terms "comprising," "including," and "having" are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0023] As described below, the disclosed embodiments include systems and methods for casting components such as turbomachinery components by molds that are heat-customized for complex geometries and varying thicknesses of components. In certain embodiments, the turbomachinery component may be a component of a compressor, a turbine, a pump, or any combination thereof. For example, the turbine may include a gas turbine, a steam turbine, a water turbine, a wind turbine, or any combination thereof. The component may include a static component or a movable component, such as a rotating component. For example, the component may include a blade or a guide vane of a turbomachinery, such as a gas turbine blade or a guide vane. Therefore, the thickness of the component may vary substantially over the entire component. The disclosed embodiments use various computer models, historical data, casting data, and component data to generate a modified or enhanced mold to generate a mold that can improve heat transfer, cooling, and solidification profiles when the mold is used to cast the component. For example, the mold may include a thickness variation that varies in a manner opposite or relative to the thickness variation of the component, thereby providing a thicker mold wall in a thinner region of the component and a thinner mold wall in a thicker region of the component. In certain embodiments, the mold has a geometry including a wall thickness variation that is computer designed and manufactured by additive manufacturing to provide control over heat transfer, cooling, and solidification. The resulting solidification profile can be a substantially flat solidification profile or a concave solidification profile. The concave solidification profile will help ensure that cooling and solidification are carried out from the inside to the outside during the casting process. The substantially flat solidification profile will help ensure that cooling and solidification are carried out in a substantially uniform manner in the inner and outer portions of the component during the casting process. The mold of the disclosed embodiment can also help reduce casting grain defects, such as stray crystals, misoriented crystals, and freckles. Discussed below is a casting process for a turbomachinery component; however, the disclosed embodiment can be used for any component in any industry.

[0024] Figure 1 1 is a block diagram of an embodiment of a manufacturing system 10 configured to provide thermal improvements when manufacturing various devices (such as components of turbomachinery). In the illustrated embodiment, the manufacturing system 10 includes a computer 12, an additive manufacturing system 14 (e.g., a 3D printing system) coupled to the computer 12, and a casting system 16 configured to cast a component 20 using a mold 18 produced by the additive manufacturing system 14. In certain embodiments, the component 20 can be a component of a turbomachinery (e.g., a turbomachinery component), wherein the turbomachinery can include a turbine, a compressor, a pump, or other equipment. For example, the manufacturing system 10 can be configured to produce blades or vanes of a turbomachinery, such as turbine guide vanes or vanes, compressor blades or vanes, pump blades or vanes, or a combination thereof, as the component 20. Therefore, the manufacturing system 10 can be used to manufacture components 20 of gas turbine engines in power plants, such as blades or vanes.

[0025] As discussed in detail below, the manufacturing system 10 facilitates improving the cooling and solidification profile of the component 20 during the casting process by customizing the mold 18 for the component 20, wherein the customization specifically includes thickness variations of the mold 18 customized for thickness variations of the component 20 to control the cooling and solidification profiles. Although the disclosed embodiments primarily discuss controlling the thickness variations of heat transfer (e.g., cooling) and solidification profiles, the mold 18 may be generated based on variations in thermal conductivity, emissivity, alloy solidification latent heat, wall thickness, or any combination thereof. In addition, the disclosed embodiments of the mold 18 are applicable to components 20 cast with single crystal, directionally solidified columnar grain structures, equiaxed grain structures, or even mixed grain structures. Mixed grain structure castings may include directionally solidified (DS) grains or single crystal grains at some locations of the component 20 cast using the mold 18 and equiaxed grains at other locations. In certain embodiments, the mold 18 may be used in conjunction with single mold casting, or in conjunction with a tree of multiple molds cast using the casting system 16.

[0026] The computer 12 may include one or more processors 22, memory 24, instructions 26 stored on and executable by the one or more processors 22 to perform various functions of a computer-aided design (CAD) system 30, and communication circuitry 28 (e.g., wired and / or wireless communication circuitry) configured to communicate with the manufacturing system 14 and the casting system 16. The computer 12 also includes casting data 32, a plurality of models 34 (such as models 36, 38, and 40), and various other data acquisition and processing devices that facilitate the operation of the CAD system 30. The CAD system 30 is configured to receive and process the casting data 32 and the plurality of models 34 to generate a CAD model 42 of the mold 18 for the part 20.

[0027] The casting data 32 and the model 34 are used to help customize the CAD model 42 of the mold 18 so that the desired heat transfer (e.g., cooling) and solidification (e.g., solidification profile) occur during casting of the part 20. Thus, the casting data 32 may include historical casting data, simulated casting data (e.g., casting data using computer simulations), test casting data (e.g., casting data using test molds to obtain feedback), or any combination thereof. The casting data may include various inputs and outputs of the casting process, where the inputs may include casting temperature, the rate of movement of the mold 18 during casting, the material used for casting, the geometry of the part 20, and the geometry of the mold 18. The outputs may include the temperature, solidification, and material properties of the part 20 resulting from casting using the mold 18, where the outputs may include spatial profiles that vary over time throughout the mold 18 and the part 20. In certain embodiments, for test casting data, one or more test molds 18 may be modeled via the CAD model 42, produced by the additive manufacturing system 14, and tested by the casting system 16 to monitor heat transfer (e.g., cooling) and solidification (e.g., solidification profile) of the part 20, such that the CAD model 42 of the mold 18 (and the mold 18 itself) may be further refined over any number of testing iterations.

[0028] Model 36 may include one or more computer simulation models of component 20, model 38 may include one or more computer simulation models of component mold 18 and / or casting process, and model 40 may include one or more computer simulation models of turbomachinery (e.g., gas turbine engine). Each of models 36, 38, and 40 may include one or more physics-based models, thermal or heat transfer models, solidification-based models, fluid-based models, existing or baseline CAD models, or any combination thereof. The thermal or heat transfer model may model temperature, heat transfer, and solidification throughout the mold 18 and component 20 to generate thermal profiles (e.g., temperature profiles, heat transfer profiles, cooling profiles, etc.), solidification profiles (e.g., liquid / solid interfaces), or any combination thereof at one or more cross-sections of the mold 18 and component 20 during the casting process. For example, model 36 and / or 38 may include a model of the casting process that includes the effects of mold thickness variations on temperature, cooling, solidification profiles, material properties, and other properties of the component 20 produced by the mold 18 during the casting process.

[0029] The CAD system 30 may be configured to generate a CAD model 42 of the component 20 such that the CAD model 42 has a variable thickness to adjust heat transfer and solidification of the component 20 during the casting process. For example, as discussed in further detail below, the CAD model 42 of the mold 18 may be customized for the component 20 to include a greater thickness to slow down heat transfer and solidification of the component 20 in thinner areas of the component 20, and a smaller thickness to speed up heat transfer and solidification of the component 20 in thicker areas of the component 20, or a combination thereof. The thickness variation of the CAD model 42 of the mold 18 may vary longitudinally along the component 20, transversely across a cross-section of the component 20, or in any combination thereof. Thus, the thickness variation in the CAD model 42 of the mold 18 is configured to help provide desired heat transfer, cooling, and solidification of the component 20 during the casting process performed by the casting system 16.

[0030] The additive manufacturing system 14 is configured to generate the mold 18 for use with the casting system 16 using the CAD model 42 of the mold 18. In the illustrated embodiment, the additive manufacturing system 14 includes a controller 44 having one or more processors 46, a memory 48, instructions 50, and a communication circuit 52 (e.g., wired and / or wireless communication circuitry) stored on the memory 48 and executable by the processor 46 to perform a desired additive manufacturing process to generate the mold 18 according to the CAD model 42, the communication circuit being configured to communicate with the computer 12 and the casting system 16. The additive manufacturing system 14 may be specifically designed to process specific materials, such as a ceramic-specific additive manufacturing system 14. For example, the additive manufacturing system 14 may include an additive ceramic 3D printing system using the CAD model 42, such as a layer-by-layer sintering system configured to additively manufacture the mold 18 using ceramic powder. In certain embodiments, the additive manufacturing system 14 may include a direct digital manufacturing (DDM) system using the CAD model 42.

[0031] The additive manufacturing system 14 also includes one or more material supply devices 54, one or more material applicators 56, one or more energy applicators 58 and one or more positioning tools 60. The material supply device 54 may include a gas supply device, a liquid supply device and a solid supply device, such as a solid powder supply device. The material supply device 54 may include a plastic material, a metal material, a ceramic material, a ceramic metal (e.g., a metal ceramic) material, or any combination thereof. For example, in the illustrated embodiment, the additive manufacturing system 14 may use a ceramic material in the material supply device 54 to generate a ceramic mold 18. However, the material may vary according to the desired heat transfer through the mold 18 and the configuration of the component 20. In certain embodiments, the ceramic material may include silicon dioxide, aluminum oxide, zircon, chromium trioxide, aluminum silicate, silicon carbide, aluminum oxide-chromium oxide-silicon dioxide, or any combination or mixture thereof configured to produce a corresponding ceramic mold 18. The material applicator 56 may include a layered applicator, a printer, a coating system, a sprayer, a jet or fluid nozzle, or any combination thereof. The energy applicator 58 may include one or more lasers, spray guns, or any other high energy source to generate a layer of material from the material supply 54 through the material applicator 56. The positioning tool 60 may include an electric drive, a fluid drive (e.g., pneumatic and / or hydraulic drive), a gear assembly or transmission, a robotic arm, a press, a conveyor, or any combination thereof. The positioning tool 60 may be configured to operate on one or more axes (such as X, Y, and Z axes) to provide three-dimensional movement of the material applicator 56, the energy applicator 58, or other equipment.

[0032] During operation, the additive manufacturing system 14 receives the CAD model 42 of the mold 18 through the controller 44, and controls the material supply device 54, the material applicator 56, the energy applicator 58 and the positioning tool 60 to provide or generate the mold 18 with a wall thickness variation according to the CAD model 42 of the mold 18. The final result of the additive manufacturing system 14 is the mold 18 with a thickness variation, which is subsequently used by the casting system 16. In certain embodiments, the manufacturing system 10 can be used in conjunction with another type of manufacturing system 14 of the CAD model 42 of the mold 18, and the other type of manufacturing system can be configured to generate a mold 18 with a wall thickness variation according to the CAD model 42. Therefore, the manufacturing system 10 is not limited to the additive manufacturing system 14, the manufacturing system 10, and any suitable process can be used to manufacture a mold 18 with a variable thickness to facilitate the desired heat transfer and solidification profile of the part 20.

[0033] The casting system 16 includes a furnace 62 having a housing 64 (such as a housing with an insulation lining), which may include a hot chamber 66 and a cold chamber 68. The housing 64 may be lined with one or more layers of insulation 70, such as refractory bricks, ceramic materials, or any combination thereof. The casting system 16 may also include a divider or partition wall 72 between the hot chamber 66 and the cold chamber 68, wherein the partition wall 72 may include an opening 74 configured to allow the mold 18 to enter the cold chamber 68 from the hot chamber 66. The furnace 62 may also include a passage door 76 in the cold chamber 68 to facilitate removal of the mold 18 after the casting process is completed. The casting system 16 may also be coupled to one or more of a material supply 78, a heating system 80, a controller 82, a cooling system 84, and a positioning system 86. In the illustrated embodiment, the material supply 78 may include one or more fluid supply devices, solid supply devices, or a combination thereof. For example, the material supply 78 may include a solid powder supply that may include plastic powder, metal powder, ceramic powder, cermet powder, or any other suitable powder material. The material supply 78 may include a conduit or injection line 88 extending from the material supply 78 to an upper hopper 90 of the mold 18. Thus, the material supply 78 is configured to transfer the desired material into the mold 18 through the upper hopper 90, which may occur before or during heating of the mold 18 within the hot chamber 66 of the furnace 62.

[0034] The heating system 80 is configured to apply heat to the hot chamber 66, as indicated by arrow 92. The heating system 80 may include a combustion system that combusts a fuel (e.g., a liquid, gaseous, or solid fuel) with an oxidant such as air. The heating system 80 is configured to apply sufficient heat 92 to the hot chamber 66 to maintain a desired temperature within the hot chamber 66 for melting or liquefying the material supplied by the material supply 78 to the mold 18.

[0035] The controller 82 may include one or more processors 94, a memory 96, and instructions 98 stored on the memory 96 and executable by the processor 94 to facilitate monitoring and control of the material supply 78, the heating system 80, the cooling system 84, and the positioning system 86. The controller 82 also includes a communication circuit 100 configured to communicate with the material supply 78, the heating system 80, the cooling system 84, and the positioning system 86 of the casting system 16, as well as with the computer 12 and the additive manufacturing system 14 via wired or wireless communications. During operation, the controller 82 is configured to control the casting process of the part 20 using the mold 18 generated by the additive manufacturing system 14 based on the CAD model 42. Specifically, the controller 82 may be configured to operate the casting system 16 using specific parameters associated with the CAD model 42, such as the temperature in the hot chamber 66 and the cold chamber 68, the movement rate of the mold 18 between the hot chamber 66 and the cold chamber 68, and other casting parameters.

[0036] The cooling system 84 is configured to apply cooling or heat transfer away from the cold chamber 68, as shown by arrow 102. For example, when the mold 18 is moved from the hot chamber 66 to the cold chamber 68, the cooling system 84 can circulate a coolant to and from the cold chamber 68 to regulate the temperature within the cold chamber 68, thereby controlling the cooling of the mold 18 and the solidification of the part 20. The cooling system 84 may include a gas cooling system, a liquid cooling system, or any combination thereof. For example, the cooling system 84 can circulate cooling air, cooling water, or another cooling hot fluid to and from the cold chamber 68. In certain embodiments, the cooling system 84 may include one or more fans to circulate an airflow or inert gas flow within the cold chamber 68 and / or between the cold chamber 68 and the external environment. However, when using the mold 18 of the disclosed embodiment, the casting system 16 can be configured to work without the cooling system 84 (such as gas cooling or other high gradient casting techniques).

[0037] The positioning system 86 is configured to move the mold 18 between the hot chamber 66 and the cold chamber 68 in a controlled manner, thereby helping to control the thermal profile and solidification profile of the part 20. For example, the positioning system 86 may include one or more electric drives, fluid drives (e.g., pneumatic drives and / or hydraulic drives), gear assemblies or transmissions, lifting assemblies, robotic arm assemblies, or any combination thereof. The positioning system 86 may be configured to move the mold in the axial direction 104 along the central axis 106 of the heating furnace 62, thereby controlling the rate at which the mold 18 enters the cold chamber 68. In certain embodiments, the positioning system 86 may also be configured to rotate the mold 18 around the central axis 106, to move the mold 18 laterally relative to the central axis 106, or any combination thereof. Each of the movements provided by the positioning system 86 may be configured to help control heat transfer away from the mold 18 and the part 20, the solidification profile of the part 20, or any combination thereof. The positioning system 86 may also be controlled by the controller 82 at least in part based on the variable thickness of the mold wall of the mold 18 to help control the heat transfer and solidification profile of the part 20.

[0038] Thus, during operation, the casting system 16 receives material from the material supply 78 into the mold 18 via the upper hopper 90, heats and liquefies the material within the mold 18 within the hot chamber 66, controls the temperature profile within the hot chamber 66 via the heating system 80, and controls the movement of the mold 18 from the hot chamber 66 to the cold chamber 68 via the positioning system 86. As the mold 18 moves from the hot chamber 66 to the cold chamber 68, the cooling system 84 is controlled by the controller 82 to provide a desired temperature profile within the cold chamber 68, thereby helping to control the transfer of heat away from the mold 18 and the cooling and solidification of the part 20 within the cold chamber 68. The variable wall thickness of the mold 18 and the rate at which the mold 18 moves from the hot chamber 66 to the cold chamber 68 help control the heat transfer and solidification profile of the part 20, as discussed in further detail below. Once the mold 18 moves from the hot chamber 66 to the cold chamber 68, the casting system 16 may continue to provide cooling to the cold chamber 68 until the mold 18 and the part 20 are sufficiently cooled and the part 20 solidifies. At this point, the casting system 16 may open the access door 76 to allow removal of the mold 18, as indicated by arrow 108. The part 20 may then be removed from the mold 18, as indicated by arrow 110.

[0039] In the illustrated embodiment, the mold 18 has a mold body 112 disposed between an upper hopper 90 and a lower hot plate or starter block 114. As described above, the upper hopper 90 is configured to help guide material from the material supply 78 into the mold body 112. The hot plate 114 is configured to help transfer heat away from the mold body 112 during the cooling and solidification of the part 20. As discussed in further detail below, the mold body 112 has a wall 116 disposed around an interior or casting chamber 118. The wall 116 surrounds the interior 118, while the exterior 120 is disposed around the wall 116. The wall 116 also has a wall thickness 122 that varies in various directions to provide more uniform cooling and solidification of the part 20, wherein the wall thickness 122 is based on the CAD model 42 of the mold 18 as described above.

[0040] In the illustrated embodiment, the wall thickness 122 may vary along one or more of an axial direction 124, a radial direction 126 substantially perpendicular to the axial direction 124, and a circumferential direction 128 disposed about the axial direction 124 relative to a central axis 130 of the mold 18. For example, at a particular axial position along the central axis 130, the wall thickness 122 may vary across a cross-sectional plane of the mold 18. Additionally, the wall thickness 122 may vary between the upper funnel 90 and the hot plate 114 in the axial direction 124 along the central axis 130. In certain embodiments, the hot plate 114 may be disposed toward an end portion 132 of the component 20, and the funnel 90 may be disposed adjacent to a base portion 134 of the component 20 cast by the casting system 16. However, the orientation of the component 20 may vary depending on the particular component and application. Other details of the mold 18 and the casting process will be discussed in further detail below.

[0041] Figure 2 is used to pass Figure 1 1 is a perspective view of an embodiment of a mold 18 for casting a component 20 of a manufacturing system 10. As shown, the mold 18 includes a mold body 112 disposed between an upper funnel 90 and a hot plate 114. The mold also includes an end portion 132 adjacent to the hot plate 114 and a base portion 134 adjacent to the upper funnel 90. Figure 2 As shown, the geometry of the mold body 112 varies between the upper funnel 90 and the hot plate 114. More specifically, the mold body 112 has a wall thickness 122 variation at various cross-sections along the central axis 130 of the mold 18. For example, the wall thickness 122 varies at each of the cross-sections at the plane taken through the mold 18 as shown by lines 4-4, 5-5, 6-6, and 7-7. As discussed in further detail below, the wall thickness 122 varies in the cross-section of the plane, and the wall thickness 122 varies in the axial direction 124 along the central axis 130.

[0042] Figure 3 yes Figure 1and Figure 2 1 is a cutaway perspective view of an embodiment of the mold 18, further illustrating the interior details of the mold body 112. In the illustrated embodiment, the mold 18 may be configured to produce a component 20 having an airfoil geometry, such as an airfoil blade or guide vane of a turbine, compressor, or other turbomachinery. Thus, the mold body 112 includes an airfoil cavity 150 having a plurality of interior portions 152 configured to provide a hollow portion of the component 20 when the casting process is complete. Thus, the airfoil cavity 150 has an interior 118 with an airfoil interior contour, while the exterior 120 also has an airfoil exterior contour separated from the interior 118 by a wall thickness 122. Likewise, the wall thickness 122 varies around the airfoil cavity 150 to facilitate the desired heat transfer and solidification profile of the component 20.

[0043] The airfoil cavity 150 extends from a leading edge 154 to a trailing edge 156, wherein the leading edge 156 and the trailing edge 154 are joined by a suction side 158 and a pressure side 160 of the interior 118. The aforementioned geometry of the airfoil cavity 150 defines the exterior of the component 20 when the casting process is completed. The exterior 120 of the mold body 112 generally follows the contour of the airfoil cavity 150 (albeit with a variable wall thickness 122), wherein the exterior 120 has a leading edge portion 162, a trailing edge portion 164, a suction side portion 166, and a pressure side portion 168 that are generally along or aligned with the leading edge 154, the trailing edge 156, the suction side 158, and the pressure side 160 of the interior 118. However, the wall thickness 122 of the wall 116 varies from the leading edge 154 to the trailing edge 156 around the airfoil cavity 150, and thus the wall thickness 122 of the wall 116 also varies from the leading edge portion 162 to the trailing edge portion 164 around the exterior 120. Additionally, the wall thickness 122 may vary in the axial direction 124 along the central axis 130 of the mold 118 , as described above.

[0044] In certain embodiments, portions of the airfoil cavity 150 defining thinner portions of the component 20 may be surrounded by thicker portions of the wall 116 (e.g., larger wall thickness 122), while portions of the airfoil cavity 150 defining thicker portions of the component 20 may be surrounded by thinner portions of the wall 116 (e.g., smaller wall thickness 122). In other words, thinner portions of the component 20 formed by the mold 18 may cool and solidify faster than thicker portions of the component 20 formed by the mold 18, and thus the mold 18 is customized for these variations in thickness and solidification rate in the component 20 by providing larger wall thickness 122 to slow cooling and solidification in the thinner portions of the component 20 and by providing smaller wall thickness 122 to accelerate cooling and solidification in the thicker portions of the component 20. In this way, customization of the mold 18 may be achieved by varying the wall thickness 122 of the mold 18 in an opposite or opposite manner to the variations in thickness of the component 20 cast in the mold 18. The wall thickness 122 variation may be based on thickness variation of the component 20 , cooling variation across the component 20 , solidification variation across the component 20 , or any combination thereof to help provide desired cooling and solidification of the component 20 during the casting process.

[0045] Figure 4 , Figure 5 , Figure 6 and Figure 7 Along Figure 2 The lines 4-4, 5-5, 6-6 and 7-7 are intercepted Figures 1 to 3 A cross-sectional view of an embodiment of the mold 18 is shown. Figure 4 , Figure 5 , Figure 6 and Figure 7 The cross-sectional views of FIG. 1 and FIG. 2 illustrate variations in wall thickness 122 at different axial locations along central axis 130, and also illustrate variations in wall thickness 122 between leading edge 154 and trailing edge 156. Specifically, as shown in each of the cross-sectional views, wall thickness 122 of wall 116 is generally thicker at trailing edge portion 164 of mold body 112, and generally thinner at leading edge portion 162 of mold body 112, corresponding to generally thinner portions of airfoil cavity 150 at trailing edge 156 and generally larger cavity portions of airfoil cavity 150 at leading edge 154. Thus, thickness 122 is generally larger for thinner regions of airfoil cavity 150 (and component 20), and generally thinner for thicker regions of airfoil cavity 150 (and component 20).

[0046] like Figure 4 , Figure 5 , Figure 6 and Figure 7As shown, a centerline or camber line 170 extends from the leading edge 154 to the trailing edge 156 of the airfoil cavity 150, wherein the camber line 170 is located midway or in the center between the suction side 158 and the pressure side 160. Along the camber line 170, the wall thickness 122 of the wall 116 may be substantially equal on both the suction side portion 166 and the pressure side portion 168 of the mold body 112 at each location along the camber line 170. As such, the wall thickness on both the suction side portion 166 and the pressure side portion 168 is equal or uniform at each location along the camber line 170 to help provide uniform heat transfer (e.g., in opposite directions toward the suction side portion 166 and the pressure side portion 168 relative to the camber line 170) at each location along the camber line 170, thereby helping provide a desired cooling profile and solidification profile for the part 20. However, as the mold body 112 extends along the camber line 170, the wall thickness 122 generally varies between the leading edge portion 162 and the trailing edge portion 164 of the mold body 112, depending on the thickness of the airfoil cavity 150 (and, therefore, the part 20). The wall thickness 122 variation is configured to help achieve more uniform heat transfer and cooling during the casting process within the casting system 16, while also helping to achieve more uniform solidification of the liquefied material within the mold 18 to form the part 20.

[0047] For example, at point 172 along the camber line 170, the wall thickness 122 may be equal at segments 174 and 176 corresponding to the suction side portion 166 and the pressure side portion 168 of the mold body 112. Similarly, at point 178 along the camber line 170, the wall thickness 122 of the wall 116 may be substantially equal at segments 180 and 182 corresponding to the suction side portion 166 and the pressure side portion 168 of the mold body 112. However, when comparing point 172 to point 178, the wall thickness 122 varies between the pair of segments 174 and 176 and the pair of segments 180 and 182. The wall thickness 122 may have similar variations in other points along the camber line 170, thereby providing variations in the wall thickness 122 to provide desired heat transfer depending on the thickness of the airfoil cavity 150 and the desired solidification profile for the cast component 20.

[0048] Figure 8 and Fig. 9 is Figure 1 Schematic diagram of an embodiment of a solidification profile 190 of material 192 of a component 20 transitioning from a liquid state 194 to a solid state 196 in a mold 18 during cooling in a casting system 16 of FIG. Figure 8As shown, the solidification profile 190 has a concave solidification profile 198, wherein during cooling in the casting system 16, the liquid state 194 of the material 198 changes from the central axis 130 outward toward the periphery 200 of the part 20 to the solid state 196. Specifically, the concave solidification profile 198 is achieved by the change in the wall thickness 122 of the mold 18 and the movement rate of the mold 18 from the hot chamber 66 to the cold chamber 68 of the casting system 16, so that the part 20 cools and solidifies from the inside out as shown by arrow 202. The solidification profile 190 (e.g., the concave solidification profile 198) of the part 20 occurs during the movement of the mold 18 from the hot chamber 66 to the cold chamber 68 as shown by arrow 104.

[0049] However, in certain embodiments, the solidification profile 190 may have another solidification profile, such as Fig. 9 The flat or substantially flat solidification profile 204 is shown. Fig. 9 In an embodiment, a flat solidification profile 204 can be achieved by controlling the variable wall thickness 122 of the mold 18 and the movement rate of the mold 18 between the hot chamber 66 and the cold chamber 68 (as shown by arrow 104), so that the material 192 can be transformed from the liquid state 194 to the solid state 196 in a substantially uniform manner between the central axis 130 and the periphery 200. Figure 1 The manufacturing system 10 can be configured to control the mold geometry by controlling the mold 18 generated by the CAD model 42 generated by the computer 12, the mold 18 generated by the additive manufacturing system 14, and various controls of the casting system 16 to achieve a concave solidification profile 198 or a flat solidification profile 204.

[0050] Fig.10 and Fig.11 yes Figures 1 to 7 18, further illustrating the thickness variation of the component 20 and the mold body 112. Fig.10 and Fig.11 As shown, the wall thickness 122 of the wall 116 of the mold body 112 generally varies longitudinally at various locations along the centerline or mid-camber line 170 between the inner portion 118 and the outer portion 120. Similarly, the thickness 210 of the part 20 generally varies longitudinally along the centerline or mid-camber line 170 between the inner portion 118 and the mid-camber line 170 of the mold 18. As will be appreciated, Fig.10 and Fig.11 The thickness 210 shown may be one-half the overall thickness of the component 20, such that the thickness 210 is equal on either side of the mid-camber line 170. Similarly, the thickness 122 of the wall 116 of the mold body 112 may be substantially equal on either side of the mid-camber line 170, depending on the particular component being constructed. Fig.10As shown, the thickness 122 generally increases while the thickness 210 decreases along the mid-camber line 170, while the thickness 122 generally decreases while the thickness 210 generally increases along the mid-camber line 170. In other words, the thickness 122 and the thickness 210 may vary in an opposite or relative (e.g., inversely proportional) manner relative to each other, such that the overall thickness 212 may control the overall heat transfer and solidification profile during cooling of the mold 18 and the part 20 in the casting system 16. In certain embodiments, the overall thickness 212 may be substantially uniform along the mid-camber line 170. However, in certain embodiments, the overall thickness 212 may also vary (e.g., increase or decrease) along the mid-camber line 170 to help control the cooling and solidification profiles to achieve the above-referenced Figure 8 and Fig. 9 The desired solidification profile 190 is discussed.

[0051] exist Fig.10 In an embodiment of the present invention, the wall 116 of the mold 18 may have a solid wall construction made of a suitable material to facilitate or control heat transfer. For example, the material 214 of the mold 18 may include a ceramic material, a metallic material, a plastic material, a composite material, a ceramic-metal material, or any combination thereof. For example, a ceramic material may be used for the material 214 of the mold 18 to control heat transfer, cooling, and the solidification profile 190 of the part 20.

[0052] exist Fig.11 In some embodiments, the wall 116 of the mold 18 may have a partially hollow construction, wherein a hollow cavity 216 is disposed in the mold body 112 of the mold 18. For example, the hollow cavity 216 may be configured to further longitudinally control heat transfer along the center arc line 170. The hollow cavity 216 may have a thickness 218 that is constant or varies longitudinally along the center arc line 170. For example, the thickness 218 of the hollow cavity 216 may generally decrease along the center arc line 170 as the wall thickness 122 decreases and / or increases as the wall thickness 122 increases. In certain embodiments, the wall 116 of the mold 18 may include a plurality of hollow cavities 216 to define a honeycomb structure, the wall 116 of the mold 18 may include a multi-wall structure having a plurality of walls separated by the hollow cavities 216, or a combination thereof. Additionally, the hollow cavities 216 may be empty, vacuumed, filled with a liquid or gas (e.g., an inert gas), or filled with a different material (e.g., an insulating material). However, any suitable arrangement, number, geometry, or configuration of hollow cavities 216 may be provided within the wall 116 of the mold body 112 to help control heat transfer and the solidification profile of the component 20 .

[0053] Fig.12 2 is a graph 230 of an embodiment of a relationship between a component thickness 232 and a mold thermal resistance 234 relative to a position 236 along the mold 18 and the component 20 (such as along the mid-arc line 170). Fig.12As shown, part thickness 232 and mold thermal resistance 234 vary in opposite or opposing (eg, inversely proportional) manner relative to one another in response to changes in position 236 along mold 18 (eg, along mid-arc line 170 and / or along central axis 130 ).

[0054] For example, the component thickness 232 generally decreases in response to a change in the position 236, while the mold thermal resistance 234 generally increases in response to a change in the position 236, or vice versa. In other words, for thicker areas of the component 20 as indicated by the component thickness 232, the mold 18 can be designed, constructed, and used with a relatively thin thickness as indicated by the mold thermal resistance 234. The thinner wall thickness 122 helps reduce the mold thermal resistance 234, thereby helping to increase the heat transfer, cooling, and solidification rates of the thicker areas of the component 20. Conversely, for thinner areas of the component 20 as indicated by the component thickness 232, the mold 18 can be designed, constructed, and used with a larger wall thickness 122 and a corresponding mold thermal resistance 234. The larger wall thickness 122 and the mold thermal resistance 234 help slow down or reduce the heat transfer, cooling, and solidification rates of the thinner areas of the component 20, so that the thinner areas of the component 20 do not solidify substantially faster than the thicker areas of the component 20. Thus, the variable wall thickness 122 of the mold 18 helps control the mold thermal resistance 234 based on the thickness of the part 20, thereby helping to achieve a desired solidification profile 190, such as described above with reference to Figure 8 and Fig. 9 discussed.

[0055] Fig.132 is a flow chart of an embodiment of a manufacturing process 250 for casting a component 20 using a mold 18, the mold having a variable wall thickness 122 customized for the component 20 as discussed in detail above. In the illustrated embodiment, the process 250 includes receiving a component model of a component to be cast in the mold, as shown in box 252. The component model may correspond to the model 36 of the component 20, which may include a turbomachinery component (e.g., a blade or guide vane of a turbine, compressor, or pump). The process 250 may also include receiving other models, such as the model 38 and the model 40. The process 250 also includes receiving casting data, as shown in box 254. As described above, the casting data 32 may include historical casting data, simulated casting data (e.g., casting data using a computer simulation), test casting data (e.g., casting data using a test mold to obtain feedback), material data, temperature data, solidification data, operating parameters of the casting system 16 for casting the component 20 using the mold 18, or any combination thereof. The process 250 may then continue to generate a mold model having a varying thermal resistance based on the varying thickness and / or solidification rate of the overall geometry of the part, as shown in block 256. The mold model may correspond to the CAD model 42 of the mold 18 as described above. The varying thermal resistance may be achieved by varying the wall thickness 122 of the wall 116 of the mold body 112 as described above, thereby facilitating achieving, for example, the above-referenced Figure 8 and Fig. 9 A solidification profile 190 is depicted.

[0056] The process 250 may then continue to manufacture the mold based on the mold model by a suitable manufacturing process (such as additive manufacturing), as shown in block 258. For example, the process 250 may use the additive manufacturing system 14 to generate the mold 18 with the variable wall thickness 122, as discussed in detail above. The process 250 may then continue to insert the mold into the casting system, as shown in block 260. For example, the mold 18 may be inserted into the hot chamber 66 of the heating furnace 62 of the casting system 16. The process 250 may then continue to supply and liquefy the material in the mold in the hot chamber of the casting system, as shown in block 262. For example, the material supply device 78 may transfer the material into the mold 18 through the upper funnel 90 so that the material is liquefied when the mold 18 is placed in the hot chamber 66 of the heating furnace 62. The process 250 may then continue to move the mold from the hot chamber of the casting system to the cold chamber, as shown in block 264. For example, the mold 18 may be moved from the hot chamber 66 to the cold chamber 68 by the positioning system 86 of the casting system 16 , where the positioning system 86 is controlled by the controller 82 to control the rate of movement of the mold 18 , as indicated by arrow 104 .

[0057] The process 20 is configured to control the solidification of the liquefied material by mold movement and the changing thermal resistance of the mold, as shown in block 266. For example, the controller 82 may control the positioning system 86 to control the movement rate of the mold 18 so that the liquefied material gradually cools and solidifies as the mold 18 moves into the cold chamber 68. In addition, the changing thermal resistance of the mold 18 may be achieved by the changing wall thickness 122 of the wall 116 of the mold body 112. The process 250 may then continue to remove the cast part from the mold, as shown in block 268. For example, the mold 18 may be removed from the heating furnace 62 through the access door 76. At this point, the part 20 may be removed from the mold 18 for final inspection and processing.

[0058] The technical effects of the disclosed embodiments may include a customized mold 18 with a variable wall thickness 122, which is configured to control heat transfer (e.g., cooling), solidification, and material properties associated with casting of a component 20, which may include a turbomachinery component. The variable wall thickness 122 generally increases for thinner portions of the component 20, and decreases for relatively thicker portions of the component 20. Thus, the variable wall thickness 122 helps slow down the cooling and solidification of portions of the component 20 that would otherwise cool and solidify too quickly, while also accelerating the cooling and solidification of portions of the component 20 that would otherwise cool and solidify too slowly. The specific geometry and size of the variable wall thickness 122 can be achieved by the CAD system 30 using various casting data 32 and models 34. The additive manufacturing system 14 can then be used to generate a mold 18 with a variable wall thickness 122, such as by additively manufacturing the mold 18 in layers to generate a complex geometry of the mold 18. During operation, the varying wall thickness 122 may vary in an axial direction 124, a radial direction 126, and / or a circumferential direction 128 relative to the central axis 130 of the mold 18 and the component 20. Advantageously, the varying wall thickness 122 of the mold 18 helps control the solidification profile 190 so that solidification of the component 20 in the casting system 16 achieves a concave solidification profile 198 or a flat solidification profile 204.

[0059] As set forth below, the subject matter described above in detail may be defined by one or more clauses.

[0060] In certain embodiments, a system includes a controller configured to receive a computer model of a mold configured to cast a component, wherein the computer model has a variable wall thickness of the mold thermally customized to a geometry of the component. The controller is configured to control a manufacturing system to produce the mold based on the computer model.

[0061] A system according to the preceding clause, wherein the variable wall thickness of the mould is designed to provide a desired solidification profile of the component during the casting process.

[0062] The system of any preceding clause, wherein the solidification profile comprises a concave solidification profile or a substantially flat solidification profile. The concave solidification profile is configured to solidify the material from a liquid state to a solid state in an outward direction from the interior to the exterior of the component during a casting process. The substantially flat solidification profile is configured to solidify the material from a liquid state to a solid state in a substantially uniform manner both inside and outside the component during a casting process.

[0063] A system according to any preceding clause, wherein the thickness of the component varies between the first end and the second end, wherein the variable wall thickness of the mould varies in an inverse manner relative to the thickness of the component.

[0064] A system as described in any preceding clause, wherein the mold comprises a turbomachinery component mold and the component comprises a turbomachinery component.

[0065] A system as described in any preceding clause, wherein the turbomachinery component comprises an airfoil blade or an airfoil vane of a gas turbine system.

[0066] A system according to any preceding clause, wherein the thickness of the turbomachinery component varies between a leading edge and a trailing edge, wherein the variable wall thickness of the mold varies in an inverse manner relative to the thickness of the turbomachinery component between the leading edge and the trailing edge.

[0067] A system according to any preceding clause, wherein the turbomachinery component includes a suction side and a pressure side on opposite sides of a mid-camber line between the leading edge and the trailing edge. The variable wall thickness includes a first variable thickness between the interior and suction side portions of the mold, wherein the variable wall thickness includes a second variable thickness between the interior and pressure side portions of the mold. The first variable thickness and the second variable thickness vary along the mid-camber line, wherein for each point along the mid-camber line, the first variable thickness and the second variable thickness are equal to each other along a line perpendicular to the respective suction side portion and pressure side portion of the mold.

[0068] A system according to any preceding clause, wherein the computer model of the mould comprises a computer aided design (CAD) model of the mould based at least in part on the casting data and one or more models associated with the part.

[0069] A system according to any preceding clause, wherein the manufacturing system comprises an additive manufacturing system.

[0070] A system according to any preceding clause, comprising an additive manufacturing system coupled to a controller.

[0071] A system according to any preceding clause, wherein the controller is configured to control the casting system to cast the component using the mold.

[0072] A system according to any preceding clause, comprising a casting system coupled to a controller, wherein the casting system comprises a heating furnace having a hot chamber and a cold chamber, wherein the controller is configured to control movement of the mold from the hot chamber to the cold chamber.

[0073] A system according to any preceding clause, comprising a mold produced by a manufacturing system, a part produced by a casting system, or a combination thereof based on a computer model of the mold.

[0074] In certain embodiments, a method includes receiving, by a controller, a computer model of a mold configured to cast a component, wherein the computer model has a variable wall thickness of the mold thermally customized to the geometry of the component. The method also includes controlling, by the controller, a manufacturing system to produce the mold based on the computer model.

[0075] The method according to the preceding clause, wherein the variable wall thickness of the mold is designed to provide a desired solidification profile of the component during the casting process, wherein the solidification profile comprises a concave solidification profile or a substantially flat solidification profile. The concave solidification profile is configured to solidify the material from a liquid state to a solid state in an outward direction from the interior to the exterior of the component during the casting process. The substantially flat solidification profile is configured to solidify the material from a liquid state to a solid state in a substantially uniform manner both inside and outside the component during the casting process.

[0076] A method according to any of the preceding clauses, wherein the mold comprises a turbomachinery component mold and the component comprises a turbomachinery component. The turbomachinery component comprises an airfoil blade or airfoil guide vane for a gas turbine system. The thickness of the turbomachinery component varies between a leading edge and a trailing edge, wherein the variable wall thickness of the mold varies in an opposite manner relative to the thickness of the turbomachinery component between the leading edge and the trailing edge. The turbomachinery component comprises a suction side and a pressure side on opposite sides of a mid-camber line between the leading edge and the trailing edge. The variable wall thickness comprises a first variable thickness between the interior and suction side portions of the mold, wherein the variable wall thickness comprises a second variable thickness between the interior and pressure side portions of the mold. The first variable thickness and the second variable thickness vary along the mid-camber line, wherein, for each point along the mid-camber line, the first variable thickness and the second variable thickness are equal to each other along a line perpendicular to the respective suction side portion and pressure side portion of the mold.

[0077] In certain embodiments, a system includes a controller configured to receive a computer model of a mold configured to cast a component, wherein the computer model has a variable wall thickness of the mold thermally customized to a geometry of the component. The controller is configured to control a manufacturing system to produce the mold based on the computer model.

[0078] A system according to the preceding clause, wherein the variable wall thickness of the mold is designed to provide a desired solidification profile of the component during the casting process, wherein the solidification profile includes a concave solidification profile or a substantially flat solidification profile, wherein the concave solidification profile is configured to solidify the material from a liquid state to a solid state in an outward direction from the inside to the outside of the component during the casting process, wherein the substantially flat solidification profile is configured to solidify the material from a liquid state to a solid state in a substantially uniform manner inside and outside the component during the casting process.

[0079] A system according to any of the preceding clauses, wherein the turbomachinery component comprises an airfoil blade or airfoil guide vane of a gas turbine system, wherein the first end is a leading edge and the second end is a trailing edge, wherein the turbomachinery component comprises a suction side and a pressure side on opposite sides of a mid-arc line between the leading edge and the trailing edge, wherein the variable wall thickness comprises a first variable thickness between an interior and suction side portion of the mold, wherein the variable wall thickness comprises a second variable thickness between an interior and pressure side portion of the mold, wherein the first variable thickness and the second variable thickness vary along the mid-arc line, wherein, for each point along the mid-arc line, the first variable thickness and the second variable thickness are equal to each other along a line perpendicular to the respective suction side portion and pressure side portion of the mold.

[0080] This written description uses examples to describe the present embodiments, including the best mode, and also enables any person skilled in the art to practice the presently disclosed embodiments, including making and using any device or system and performing any combined methods. The patentable scope of the presently disclosed embodiments is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. A system comprising: A controller, the controller being configured to: receiving a computer model of a mold configured to cast a component, wherein the computer model has a variable wall thickness of the mold thermally tailored to a geometry of the component; as well as A manufacturing system is controlled to produce the mold based on the computer model.

2. The system of claim 1, wherein the variable wall thickness of the mold is designed to provide a desired solidification profile of the component during casting.

3. The system of claim 2, wherein the solidification profile comprises a concave solidification profile or a substantially flat solidification profile, wherein the concave solidification profile is configured to solidify the material from a liquid state to a solid state in an outward direction from an interior to an exterior of the component during the casting process, wherein the substantially flat solidification profile is configured to solidify the material from the liquid state to the solid state in a substantially uniform manner at the interior and the exterior of the component during the casting process.

4. The system of claim 1, wherein a thickness of the component varies between a first end and a second end, wherein the variable wall thickness of the mold varies in an inverse manner relative to the thickness of the component. 5 . The system of claim 1 , wherein the mold comprises a turbomachinery component mold and the component comprises a turbomachinery component. 6 . The system of claim 5 , wherein the turbomachinery component comprises an airfoil blade or an airfoil vane of a gas turbine system.

7. The system of claim 5, wherein the thickness of the turbomachinery component varies between a leading edge and a trailing edge, wherein the variable wall thickness of the mold varies in an inverse manner relative to the thickness of the turbomachinery component between the leading edge and the trailing edge.

8. The system of claim 7, wherein the turbomachinery component includes a suction side and a pressure side on opposite sides of a camber line between the leading edge and the trailing edge, wherein the variable wall thickness includes a first variable thickness between an interior portion of the mold and a suction side portion, wherein the variable wall thickness includes a second variable thickness between the interior portion of the mold and a pressure side portion, wherein the first variable thickness and the second variable thickness vary along the camber line, and wherein For each point along the camber line, the first variable thickness and the second variable thickness are equal to one another along a line perpendicular to the respective suction side portion and the pressure side portion of the mold.

9. The system of claim 1, wherein the computer model of the mold comprises a computer-aided design (CAD) model of the mold based at least in part on casting data and one or more models associated with the part.

10. The system of claim 1, wherein the manufacturing system comprises an additive manufacturing system.

11. The system of claim 10, comprising the additive manufacturing system coupled to the controller.

12. The system of claim 1, wherein the controller is configured to control a casting system to cast the component using the mold.

13. The system of claim 12, comprising the casting system coupled to the controller, wherein the casting system comprises a furnace having a hot chamber and a cold chamber, wherein the controller is configured to control movement of the mold from the hot chamber to the cold chamber.

14. The system of claim 1, comprising the mold produced by the manufacturing system, the part produced by the casting system, or a combination thereof based on the computer model of the mold.

15. A method comprising: receiving, by a controller, a computer model of a mold configured to cast a component, wherein the computer model has a variable wall thickness of the mold thermally tailored to a geometry of the component; as well as A manufacturing system is controlled by the controller to produce the mold based on the computer model.

16. The method of claim 15, wherein the variable wall thickness of the mold is designed to provide a desired solidification profile of the component during a casting process, wherein the solidification profile comprises a concave solidification profile or a substantially flat solidification profile, wherein the concave solidification profile is configured to solidify the material from a liquid state to a solid state in an outward direction from an interior to an exterior of the component during the casting process, wherein the substantially flat solidification profile is configured to solidify the material from the liquid state to the solid state in a substantially uniform manner at the interior and the exterior of the component during the casting process.

17. The method of claim 15, wherein the mold comprises a turbomachinery component mold and the component comprises a turbomachinery component, wherein the turbomachinery component comprises an airfoil blade or an airfoil guide vane for a gas turbine system, wherein a thickness of the turbomachinery component varies between a leading edge and a trailing edge, wherein the variable wall thickness of the mold varies in an opposite manner relative to the thickness of the turbomachinery component between the leading edge and the trailing edge, wherein the turbomachinery component comprises a suction side and a pressure side on opposite sides of a camber line between the leading edge and the trailing edge, wherein the variable wall thickness comprises a first variable thickness between an interior and suction side portion of the mold, wherein the variable wall thickness comprises a second variable thickness between the interior and pressure side portion of the mold, wherein the first variable thickness and the second variable thickness vary along the camber line, and wherein For each point along the camber line, the first variable thickness and the second variable thickness are equal to one another along a line perpendicular to the respective suction side portion and the pressure side portion of the mold.

18. A system comprising: A mold configured to cast a component, wherein the mold has a variable wall thickness thermally tailored to a geometry of the component, wherein the variable wall thickness of the mold varies in an inverse manner relative to a thickness of the component between a first end and a second end, wherein the mold comprises a turbomachinery component mold and the component comprises a turbomachinery component.

19. The system of claim 18, wherein the variable wall thickness of the mold is designed to provide a desired solidification profile of the component during a casting process, wherein the solidification profile comprises a concave solidification profile or a substantially flat solidification profile, wherein the concave solidification profile is configured to solidify the material from a liquid state to a solid state in an outward direction from an interior to an exterior of the component during the casting process, wherein the substantially flat solidification profile is configured to solidify the material from the liquid state to the solid state in a substantially uniform manner at the interior and the exterior of the component during the casting process.

20. The system of claim 18, wherein the turbomachinery component comprises an airfoil blade or vane for a gas turbine system, wherein the first end is a leading edge and the second end is a trailing edge, wherein the turbomachinery component comprises a suction side and a pressure side on opposite sides of a camber line between the leading edge and the trailing edge, wherein the variable wall thickness comprises a first variable thickness between an interior and suction side portion of the mold, wherein the variable wall thickness comprises a second variable thickness between the interior and pressure side portion of the mold, wherein the first variable thickness and the second variable thickness vary along the camber line, and wherein For each point along the camber line, the first variable thickness and the second variable thickness are equal to one another along a line perpendicular to the respective suction side portion and the pressure side portion of the mold.

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