Casting Mold Thermocouple Array for Mushy Zone Control

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Solution Overview

Problem

In multi-shot/pour casting processes, accurately controlling the transition zone between different alloys in gas turbine engine components is challenging due to uneven cooling and heating, leading to inconsistencies in the mushy zone vertical span, which affects the quality and consistency of the final product.

Innovation Solution

A casting mold with vertically spaced thermocouples is used to monitor temperature and position during the withdrawal process, allowing for precise determination of the solidus and liquidus fronts and calculation of the mushy zone vertical span, enabling controlled pouring of multiple alloys to achieve a desired transition zone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multi-shot/pour casting is used to create multi-alloy components, then product functionality and performance are improved, but manufacturing precision deteriorates due to inconsistent mushy zone vertical span

Engineering Contradiction:

Improvemulti-alloy component capabilityVSAvoidmushy zone vertical span consistency

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent implements a feedback control system using thermocouples to monitor temperature at multiple locations within the mold. The control system receives temperature data, calculates mushy zone vertical span, and adjusts process parameters (withdrawal rate, heating power) to maintain consistent mushy zone characteristics across different production cycles, thereby resolving the precision inconsistency issue

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent dynamically adjusts critical process parameters including mold withdrawal rate, heating zone temperature, and heating power based on real-time temperature measurements. By changing these parameters adaptively rather than using fixed settings, the system maintains consistent mushy zone vertical span despite variations in material properties or environmental conditions

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If real-time temperature monitoring with multiple thermocouples is implemented, then manufacturing precision is improved through better mushy zone control, but device complexity increases

Engineering Contradiction:

Improvemushy zone vertical span controlVSAvoidthermocouple array and control system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent divides the temperature monitoring system into multiple discrete thermocouple measurement points positioned at specific locations within the mold. This segmentation allows independent measurement of temperature gradients, enabling precise calculation of mushy zone vertical span while maintaining modular system architecture that simplifies implementation and maintenance

Inventive Principle:

Principle #1Segmentation

3Manufacturing precision

If mold withdrawal rate is optimized for consistent mushy zone, then manufacturing precision is improved, but productivity decreases due to slower production cycle

Engineering Contradiction:

Improvemushy zone vertical span consistencyVSAvoidcasting production rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent transitions from a static, fixed withdrawal rate to a dynamic withdrawal system that adjusts speed based on real-time temperature feedback. The withdrawal rate is dynamically optimized to maintain consistent mushy zone characteristics while maximizing production efficiency, resolving the contradiction between precision and productivity

Inventive Principle:

Principle #15Dynamics

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 method ensures consistent and controlled multi-shot/pour casting by allowing for iterative parameter adjustments to achieve a stable mushy zone vertical span, improving the quality and consistency of gas turbine engine components by optimizing the transition zone between alloys.

Implementation Method 1

A plurality of thermocouples are vertically-spaced from each other on the shell

Methodology Applied

Scientific EffectThermocouple: Thermocouple

Implementation Method 2

accurately controlling the transition zone between different alloys in gas turbine engine components is challenging due to uneven cooling and heating

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentUS11045871B2Casting molds, manufacture and use methods

Publication Date: 2021.06.29 RTX CORP

AI summary

A casting mold (260) comprises a shell (262) extending from a lower end (264) to an upper end (266) and having: an interior space (280) for casting metal; and an opening (268) for receiving metal to be cast. A plurality of thermocouples (900) are vertically-spaced from each other on the shell.