Casting Core Metal Jacket for Small Fluid Machine Channels
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Solution Overview
Problem
Existing casting processes for fluid machine housings, particularly large ones like steam turbines and compressors, face challenges in creating channels with inner diameters less than 60 mm due to excessive thermal stress and mineralization issues, leading to difficulties in removing the core material and often resulting in the need to discard the entire housing.
Innovation Solution
A casting core design featuring a channel body with a metal jacket that surrounds a core material, allowing for the creation of housing channels with inner diameters less than 60 mm by ensuring the metal jacket fuses with the casting material, reducing thermal shock, and facilitating easy removal of the core material post-casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If thin-walled channels are created in cast housing using conventional core material, then channel miniaturization is achieved, but thermal shock and mineralization occur causing core material adhesion
Solution Approach 1:
The channel body is segmented into two distinct parts: a core material inner section and a metal jacket outer section. This segmentation allows each material to serve its specific function - the core material forms the channel shape while the metal jacket prevents adhesion and facilitates removal.
Solution Approach 2:
The channel body uses a composite structure combining core material (e.g., chromium ore sand) and metallic material (e.g., steel) in a single component. This composite design leverages the shape-forming capability of the core material while the metal jacket provides thermal resistance and prevents mineralization adhesion.
2Shape
If conventional core material is used for thin channels, then channel formation is achieved, but thermal shock causes mineralization and core material adhesion to housing
Solution Approach 1:
The metal jacket acts as an intermediary layer between the molten casting material and the core material. It absorbs and distributes thermal shock, preventing direct thermal contact that would cause mineralization and adhesion of the core material to the housing.
Solution Approach 2:
The metal jacket is applied locally only to the channel body, specifically where thermal shock risks are highest. This localized quality enhancement protects the critical channel formation area without requiring the entire core to be metal, maintaining cost-effectiveness.
3Length of moving object
If channel inner diameter is reduced below 60 mm, then miniaturization is achieved, but core material cannot be removed requiring housing discard
Solution Approach 1:
The design enables selective discarding of only the metal jacket and core material from the channel body, while recovering and retaining the expensive cast housing. The metal jacket and core material are designed to be removable as a unit, avoiding complete housing discard.
4Productivity
If conventional casting core is used, then housing casting is achieved, but channels require minimum 60 mm diameter for successful core removal
Solution Approach 1:
The invention changes the material composition parameter of the channel body, incorporating metallic material in the form of a metal jacket. This parameter change enables channel inner diameters to be reduced from the conventional 60 mm minimum to as small as 25 mm while maintaining successful core removal capability.
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
Enables the production of small and precise housing channels with inner diameters as low as 25 mm, while preventing core material adhesion and allowing for the creation of channels with variable cross-sections, thus enhancing the manufacturing efficiency and flexibility of fluid machine housings.
Implementation Method 1
the metal material of the channel body shell is adapted to the casting material, in particular that the metal material corresponds to the casting material... the metal material of the channel body shell melts down after some time and bonds with the casting material
Implementation Method 2
the channel body shell radially surrounds the channel body core... the channel body shell ensures the mechanical stability of the channel body
Data Source
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AI summary
The present invention relates to a casting core (10) for a cast housing (2) of a fluid machine (1), the housing (2) comprising a metal casting material (6), the casting core (10) comprising a core body (11) for forming cavities (3) in the housing (2) of the fluid machine (1) during a casting process, the core body (11) comprising a core material (12). The invention further relates to a housing (2) for a fluid machine (1) made of a cast metal material (6), wherein production of the housing (2) comprises a casting process in which casting is performed around a casting core (10). The invention further relates to a fluid machine (1) comprising a housing (2).