Additive Core for Gas Turbine Cooling Circuit Casting

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Solution Overview

Problem

Conventional core casting processes struggle to efficiently and repeatedly produce small, complex features required for internal cooling circuits in gas turbine engine components, such as turbine blades, due to limitations in casting small features effectively.

Innovation Solution

A core for casting internal cooling circuits in gas turbine engine components is created by combining a base core portion, typically made of a ceramic material, with an additively manufactured additive core portion, often made of molybdenum, which forms pin-shaped protrusions or trailing edge crossovers, allowing for the creation of intricate features that are difficult to produce via conventional methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional core casting processes are used, then manufacturing simplicity is maintained, but manufacturing precision and capability for small complex features deteriorate

Engineering Contradiction:

Improveprecision of small complex featuresVSAvoidcomplexity of core structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The core is divided into two distinct portions: a base core portion made of ceramic material and an additive core portion made of metal material (such as molybdenum). This segmentation allows each portion to be manufactured using the most suitable process for its specific requirements, with the additive portion providing complex features that cannot be achieved through conventional casting alone.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The core utilizes composite construction by combining ceramic material for the base portion and metal material for the additive portion. This composite approach leverages the advantages of both materials: ceramic provides thermal stability and structural integrity, while metal enables precise additive manufacturing of complex geometries like pin-shaped protrusions and trailing edge crossovers.

Inventive Principle:

Principle #40Composite materials

2Productivity

If conventional casting methods are used, then manufacturing process simplicity is maintained, but productivity and repeatability for complex features deteriorate

Engineering Contradiction:

Improveefficiency of complex feature manufactureVSAvoidease of core manufacturing

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The base core portion is manufactured in advance using conventional ceramic casting processes, establishing a stable foundation. Subsequently, the additive core portion is added to the pre-formed base portion, allowing complex features to be built up systematically. This preliminary action enables better control over the manufacturing process and improves repeatability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The base core portion acts as an intermediary substrate that supports the additive core portion. This intermediary structure allows the complex features to be manufactured additively with high precision while maintaining the overall structural integrity through the ceramic base, thereby improving productivity without completely abandoning conventional manufacturing advantages.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If single-material conventional casting is used, then manufacturing simplicity is maintained, but adaptability for different material properties deteriorates

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Different portions of the core are made from different materials optimized for their specific functions. The ceramic base core portion provides thermal stability and structural support, while the metal additive core portion enables precise formation of complex cooling circuit features. This local quality differentiation allows each material to be selected based on its most suitable properties for that specific region.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11059093B2Additively manufactured core for use in casting an internal cooling circuit of a gas turbine engine component

Publication Date: 2021.07.13 RTX CORP

AI summary

A core for use in casting an internal cooling circuit within a gas turbine engine component includes a base core portion and an additive core portion additively manufactured to the base core portion. A method of manufacturing a core for use in casting an internal cooling circuit within a gas turbine engine component including additively manufacturing an additive core portion to a base core portion.