Multi-Walled Airfoil Core Concurrent Injection Molding
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Solution Overview
Problem
Current manufacturing techniques for multi-walled airfoil cores in gas turbine engines are complex, costly, and time-consuming, requiring multiple core assembly and expensive die tooling, which increases tolerances and production time.
Innovation Solution
A method of forming a multi-walled airfoil core by concurrently forming and connecting core components, such as the leading edge, serpentine, tip flag, hybrid skin, and trailing edge cores in a single die, using injection molding with ceramic or refractory metal materials, and assembling them to simplify the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate core components are assembled using traditional techniques, then the airfoil core can be formed with complex internal passages, but the manufacturing process becomes complex, costly, and time-consuming with increased tolerances
Solution Approach 1:
The patent merges multiple separate core components (leading edge core, serpentine core, tip flag core, hybrid skin core, trailing edge core) into a single integrated multi-walled airfoil core structure. This is achieved by concurrently forming all core components in a single die during injection molding, eliminating the need for complex assembly operations and reducing positioning tolerances while maintaining the complex internal passage geometry required for thermal cooling
2Productivity
If traditional multi-step core assembly methods are used, then complex internal passages can be created, but production time and cost increase
Solution Approach 1:
The patent applies preliminary action by concurrently forming all core components (leading edge, serpentine, tip flag, hybrid skin, and trailing edge cores) in a single die during the injection molding process. This preliminary integration eliminates subsequent assembly steps, significantly reducing production time while maintaining the complex internal passage structure necessary for effective thermal cooling of the airfoil
3Ease of manufacture
If multiple separate core components are assembled, then internal cooling passages can be formed, but assembly time and cost increase
Solution Approach 1:
The patent combines multiple core components into a single integrated structure formed concurrently in one die during injection molding. This merging eliminates the need for separate assembly operations, simplifying the manufacturing process and reducing assembly time while preserving the complex internal cooling passage geometry required for effective thermal management of the airfoil
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 approach simplifies the manufacturing of multi-walled blades, reduces tolerances and assembly time, and allows for better control of core positioning, resulting in a quicker and more cost-effective production of high-performance airfoil cores with improved thermal cooling effectiveness.
Implementation Method 1
concurrently forming and connecting core components, such as the leading edge, serpentine, tip flag, hybrid skin, and trailing edge cores in a single die, using injection molding
Data Source
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AI summary
A method of forming an airfoil, includes forming a hybrid skin core, a tip flag core, and a trailing edge core. The hybrid skin core, tip flag core, and trailing edge core are connected to form a first core portion. A leading edge core and a serpentine core are formed. The first core portion, the leading edge core, and the serpentine core are assembled together to form an airfoil core. An airfoil is formed around the airfoil core.