Ceramic Core Burner Arrays for Airfoil Casting
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Solution Overview
Problem
The existing methods for making ceramic cores for airfoil casting are time-consuming due to the need for a long kiln fire process and can result in voids that require additional ceramic material to fill, which complicates the process and may affect the accuracy of the core's dimensions.
Innovation Solution
A method where a ceramic core is formed with a configuration matching the airfoil cavity and positioned between arrays of burners to burn off organic materials, eliminating the need for a long kiln fire and allowing for the deposition of ceramic material to fill voids, while maintaining the core's dimensions by supporting it upright during the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a long kiln fire process is used to heat and sinter the ceramic core, then the core strength and surface condition are improved, but the processing time increases significantly
Solution Approach 1:
The patent changes the heating parameters by using high-temperature burners (1000-1500°C) for a shorter duration (1-5 minutes) instead of traditional long kiln firing. This parameter change achieves rapid burning off of organic materials while maintaining core integrity, significantly reducing processing time from 24 hours to approximately 5 minutes.
Solution Approach 2:
The patent replaces the traditional mechanical kiln firing system with a burner-based thermal processing system. The burners provide direct, controlled heat application that achieves the same sintering effect much faster, substituting the slow thermal diffusion process of traditional kilns with a more efficient combustion-based heating method.
2Reliability
If the ceramic core is heated at high temperature for a long duration, then the organic materials are completely burned off, but the core dimensions may deform
Solution Approach 1:
The patent applies preliminary action by supporting the ceramic core in an upright position on a support block before and during the burning process. This preliminary positioning prevents dimensional deformation by providing stable support, allowing the core to withstand the thermal stress of rapid heating without warping or deforming.
Solution Approach 2:
The patent uses periodic action by applying heat in a controlled, cyclic manner through the burner arrays. The heat is applied periodically to different zones of the core, allowing uniform burning off of organic materials while preventing localized thermal stress that could cause deformation. This periodic heating pattern ensures complete burn-off while maintaining dimensional accuracy.
3Manufacturing precision
If the ceramic core is supported in an upright orientation during burning, then dimensional accuracy is maintained, but the support structure complexity increases
Solution Approach 1:
The patent uses a simple, disposable support block that can be easily manufactured and discarded after use. This inexpensive support structure provides the necessary upright positioning during the critical burning phase without adding significant complexity to the overall system. The support block is a simple geometric form that accomplishes its function without requiring complex mechanisms.
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 significantly reduces processing time, minimizes deformation, and ensures precise dimensional accuracy of the ceramic core, enabling better tolerance ranges and efficient sintering of the core without the need for extensive heat treatment.
Implementation Method 1
Flames from the arrays of burners are directed against surfaces on opposite sides of the ceramic core. This results in a burning of organic material contained in the ceramic core.
Implementation Method 2
burning of organic material contained in the ceramic core
Data Source
AI summary
A ceramic mixture is shaped to form a ceramic core having a configuration which corresponds to the configuration of a cavity in an airfoil. The ceramic core is positioned between a plurality of arrays of burners. Flames from the burners burn organic material contained in the ceramic core. During burning of the organic material, the core is upright with a longitudinal central axis of the core in a generally vertical orientation. The ceramic core may be dipped in a ceramic material after having performed the step of burning organic material and prior to additional heat treatment of the ceramic core.