Ceramic Core Setter Posts for Precise Multi-Wall Casting
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Solution Overview
Problem
Maintaining relative spacing and alignment of ceramic core segments during firing is challenging, particularly for multi-wall castings with multiple core pieces, leading to variability in wall thickness and casting precision.
Innovation Solution
A core setter with protruding posts or bumpers supports the legs of the ceramic core to maintain a predetermined minimum separation between core segments, ensuring precise alignment and spacing during firing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple core pieces are stacked to form multi-wall castings, then the complexity of the core assembly increases, but the manufacturing precision deteriorates due to accumulated spacing variability
Solution Approach 1:
The patent introduces setter posts as intermediary elements between core segments. These posts act as mediators that maintain precise spacing relationships between multiple core pieces during firing. The posts are positioned at critical locations where spacing control is needed, and they provide a reference framework that ensures consistent gaps between core segments, thereby resolving the accumulation of spacing variability in multi-wall casting assemblies.
Solution Approach 2:
The patent employs physical parameters of the setter posts (such as their height, diameter, and material properties) to control the spacing between core segments. By carefully selecting and adjusting these parameters, the system maintains predetermined minimum separations between core pieces during the firing process. The posts are designed with specific dimensions that directly determine the gap sizes, allowing precise control over the final wall thickness and spacing in the multi-wall casting.
2Device complexity
If core segments are positioned closely to maintain compact assembly, then the device complexity decreases, but the manufacturing precision deteriorates due to insufficient spacing control
Solution Approach 1:
The setter posts serve as intermediary reference elements that enable compact core segment positioning while maintaining precise spacing. The posts are integrated into the setter structure and provide fixed reference points that guide the placement of core segments. This allows the core assembly to remain compact and simple in structure while the posts ensure that minimum spacing requirements are met, thus resolving the conflict between simplicity and precision.
Solution Approach 2:
The setter posts are pre-positioned in the setter before core segments are assembled. This preliminary action establishes a fixed spatial framework that guides the subsequent placement of core segments. By having the posts in place first, the system ensures that when core segments are positioned against them, the spacing and alignment are automatically controlled, simplifying the assembly process while maintaining precision.
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 ensures consistent wall thickness and improved casting precision by maintaining core segment alignment, reducing variability and enhancing the quality of airfoil components in gas turbine engines.
Implementation Method 1
firing the core in the setter to harden the core
Data Source
AI summary
A method for firing a ceramic core includes: placing the core in a setter, the setter having a plurality of protruding setter posts between second legs of the core and with distal ends supporting first legs of the core; and firing the core in the setter to harden the core. During the firing, the setter posts maintain a predetermined minimum separation between the first legs and the second legs.