Casting Core for Baffle Landings in Airfoil Investment Casting
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Solution Overview
Problem
High manufacturing tolerances in the formation of baffle landings for gas turbine engine airfoils lead to variability in the gap between baffles and airfoils, affecting cooling air effectiveness and installation complexity.
Innovation Solution
A method and casting core approach where the baffle landings are formed using a casting core instead of wax, reducing tolerances and variability, ensuring precise placement and improved cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wax is used to form baffle landings in investment casting, then the manufacturing process is simple and cost-effective, but the manufacturing precision and tolerance control deteriorate
Solution Approach 1:
The patent changes the material parameter from wax to ceramic slurry for forming baffle landings. Ceramic slurry allows for tighter tolerance control and more precise dimensional accuracy compared to wax, directly addressing the manufacturing precision issue while maintaining compatibility with the investment casting process
Solution Approach 2:
The patent introduces a ceramic slurry intermediary layer that is applied to the wax pattern before shell formation. This intermediary layer provides the precise baffle landing geometry and tolerance control, while the wax pattern continues to serve its function as the basic pattern form, combining the advantages of both materials
2Ease of manufacture
If traditional wax-based investment casting is used for baffle landings, then the production cost is low, but the cooling air effectiveness deteriorates due to gap variability
Solution Approach 1:
The patent applies ceramic slurry (a fluid-like material) to the wax pattern using a spray or dip application method. This pneumatic/hydraulic application ensures uniform thickness and precise replication of the baffle landing geometry, reducing gap variability and improving cooling air effectiveness
Solution Approach 2:
The patent changes the physical and chemical parameters of the pattern material from wax to ceramic slurry. Ceramic slurry provides better dimensional stability, lower shrinkage, and more consistent surface finish, all of which contribute to reduced gap variability and improved cooling effectiveness
3Ease of manufacture
If wax is used to form baffle landings, then the manufacturing process is straightforward, but the installation complexity increases due to variability in baffle placement
Solution Approach 1:
The patent performs preliminary action by forming the baffle landings with precise geometry and tolerance during the casting process itself. The ceramic slurry is applied to the wax pattern before shell formation, ensuring that the baffle landings are pre-formed with accurate dimensions and positions, eliminating the need for post-casting adjustments during installation
Data Source
AI summary
A method and casting core for forming a landing for welding a baffle inserted into an airfoil are disclosed, wherein the baffle landing of the blade or vane is formed in investment casting by the casting core rather than by wax, reducing tolerances and variability in the location of the baffle inserted into the cooling cavity of airfoil when the baffle is welded to the baffle landing.