Ceramic Core Setter Posts for Precise Leg Spacing During Firing
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Solution Overview
Problem
Maintaining relative spacing of ceramic core segments during firing for multi-wall castings in gas turbine engines is challenging, leading to variability in wall thickness and positioning issues.
Innovation Solution
A core setter with protruding setter posts maintains a predetermined minimum separation between core legs, using either unitary or separate posts, to ensure precise spacing and alignment during the firing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate core pieces are stacked to form multi-wall castings, then complex internal passageways can be created, but maintaining relative spacing between core segments becomes difficult leading to wall thickness variability
Solution Approach 1:
The patent introduces core ties as intermediary elements that connect adjacent core segments. These core ties act as mediators to maintain precise spacing and relative positioning between separate core pieces during the casting process, thereby ensuring consistent wall thickness while enabling complex internal passageway configurations.
Solution Approach 2:
The patent divides the core structure into multiple separate segments or pieces that are stacked to form multi-wall castings. This segmentation allows for complex internal passageway designs while the segments are connected through core ties to maintain precise spacing, resolving the contradiction between design complexity and dimensional precision.
2Adaptability or versatility
If multiple separate core pieces are used for multi-wall castings, then diverse passageway configurations are achievable, but positioning variability increases due to stacked tolerance issues
Solution Approach 1:
Core ties serve as intermediary components that physically connect adjacent core segments and maintain their relative positioning. By introducing these intermediary elements, the system achieves precise positioning control across multiple stacked core pieces, enabling diverse passageway configurations while minimizing accumulated tolerance errors.
Solution Approach 2:
The core ties are pre-positioned and integrated into the core assembly before casting. This preliminary action ensures that the spacing and relative positioning of core segments are established in advance, preventing positioning variability during the casting process and maintaining measurement precision.
3Productivity
If traditional core holding methods are used, then simple castings can be produced, but multi-wall castings with multiple core segments experience spacing maintenance issues during firing
Solution Approach 1:
The core ties act as intermediary elements that maintain spacing between core segments during the firing process. This solution enables efficient production of multi-wall castings by allowing multiple core segments to be stacked and fired together as a single assembly, while the core ties ensure precise spacing is maintained throughout the process.
Solution Approach 2:
The patent combines multiple separate core segments into a single integrated core assembly through the use of core ties. This merging allows all segments to be fired simultaneously in one operation, improving productivity while the core ties maintain the precise spacing required for manufacturing quality.
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
Ensures precise registry and consistent wall thicknesses in cast airfoil elements, improving the casting process efficiency and reducing scrap rates.
Implementation Method 1
the setter posts maintain a predetermined minimum separation between the first legs and the second legs
Implementation Method 2
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.