Adjustable Pin Core Reformer for Gas Turbine Casting
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Solution Overview
Problem
The lost wax investment casting process for gas turbine components often results in unsuitably thin walls due to core misalignment caused by geometric imprecisions, which can lead to catastrophic failures, as existing reforming tools lack the necessary adjustability to correct these deficiencies before the core is set.
Innovation Solution
A core pattern reforming tool with adjustable pins and a cooling air system allows for selective adjustment and solidification of the core pattern, enabling precise alteration of surface features and wall thicknesses within the tool before the core is fired.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing reforming tools are used, then the core pattern can be formed, but the core pattern cannot be adjusted for misalignment corrections
Solution Approach 1:
The reforming tool incorporates adjustable pins that can be dynamically repositioned along the core pattern surface, allowing the tool to adapt to different misalignment scenarios. The pins can be moved to various locations and adjusted to different heights, transforming a static tool into a dynamic one that can correct multiple types of geometric imprecisions.
Solution Approach 2:
The tool allows modification of physical parameters of the core pattern by adjusting the pin positions and depths. By changing the parameters of the pins (position, height, orientation), the tool can alter the core pattern geometry to achieve proper alignment and wall thickness distribution.
2Manufacturing precision
If the core pattern is adjusted after formation, then alignment can be corrected, but the core structure loses stability
Solution Approach 1:
The tool performs alignment corrections during the formation process itself, before the core structure becomes fully stable. By adjusting the pins while the core material is still pliable, the corrections are made preliminarily, allowing the core to set in its corrected position without requiring post-formation adjustments that would compromise structural stability.
Solution Approach 2:
The tool exploits the phase transition of the core material from a pliable state to a solidified state. Adjustments are made while the material is in its pliable phase, allowing easy deformation by the pins. Once the desired alignment is achieved, the material transitions to its solid phase, locking in the corrected geometry and maintaining structural stability.
3Reliability
If wall thickness is increased to prevent failure, then component safety improves, but material usage and cost increase
Solution Approach 1:
The tool enables local adjustment of wall thickness by positioning pins at specific locations on the core pattern. Rather than uniformly increasing wall thickness throughout the entire component, the pins can be adjusted to add material only where needed to correct misalignment and prevent thin-wall failures, optimizing material usage while maintaining reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures accurate dimensional accuracy of gas turbine components by allowing for real-time adjustments and solidification of the core pattern, reducing the likelihood of defects and enhancing the mechanical and thermal integrity of the final cast components.
Implementation Method 1
The tool includes a cooling air flow path configured to receive cooling air and direct the cooling air onto the core pattern
Implementation Method 2
The core pattern is formed of a pliable material and is cooled to a point where the material sets in a solid configuration
Data Source
AI summary
A tool for reforming a core pattern. A method of reforming a core pattern comprises opening a core reformer tool. The core reformer tool has a first portion and a second portion facing the first portion. The first portion includes a concave member and a first adjustable pin. The second portion includes a convex member and a second adjustable pin. The method includes positioning the core pattern in the core reformer tool and closing the core reformer tool. The method comprises adjusting at least one of the first adjustable pin and the second adjustable pin to alter a surface of the core pattern. The method includes directing cooling air through the core reformer tool to solidify the core pattern and opening the core reformer tool to remove the core pattern.