Ceramic Core-Shell Mold for Turbine Blade Cooling Holes

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Solution Overview

Problem

Conventional methods for manufacturing turbine blades and stator vanes using investment casting struggle with producing intricate internal geometries and fine details, such as effusion cooling holes, due to limitations in printing resolution and support structures in traditional powder bed and selective laser sintering processes.

Innovation Solution

The use of direct light processing (DLP) for additive manufacturing of ceramic core-shell molds, which allows for the production of thin filaments spanning the core and shell to create fine cooling holes and intricate patterns, and the application of a ceramic outer layer to enhance structural integrity and thermal properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional powder bed or selective laser sintering processes are used for additive manufacturing of ceramic molds, then manufacturing capability is provided, but printing resolution and ability to produce fine details are insufficient

Engineering Contradiction:

Improveprinting resolutionVSAvoidmanufacturing capability

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the fundamental manufacturing parameter from powder-based sintering to liquid photopolymerization, enabling resolution improvements while maintaining additive manufacturing capability. The liquid ceramic photopolymer allows for much finer feature resolution compared to powder bed processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical powder bed system with a liquid photopolymerization system using DLP technology. This substitution enables optical-level precision through light-based curing rather than mechanical layer-by-layer powder deposition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If thin filaments are used to create fine cooling holes, then manufacturing precision is improved, but structural integrity of the mold may be compromised

Engineering Contradiction:

Improvefine detail capabilityVSAvoidstructural integrity

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The patent uses a composite ceramic-photopolymer material system where the liquid ceramic photopolymer provides both the thin filament capability for fine details and the structural integrity after curing. The composite nature allows simultaneous achievement of precision and strength.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the material state from powder to liquid photopolymer, enabling the formation of thin filaments that maintain structural integrity through photopolymerization. The liquid state allows for continuous material deposition at fine scales, and the curing process provides immediate structural strength.

Inventive Principle:

Principle #35Parameter changes

3Strength

If ceramic outer layer is applied to enhance structural integrity, then strength is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the core mold material and outer shell material into a single integrated ceramic-photopolymer structure. This eliminates the need for separate manufacturing and assembly steps, reducing overall manufacturing complexity while maintaining enhanced structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite ceramic-photopolymer material that inherently provides both core and shell functions in a single material system, eliminating the need for separate ceramic outer layer application processes and reducing manufacturing steps.

Inventive Principle:

Principle #40Composite materials

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 turbine blades with complex cooling hole patterns and improved thermal management, reducing manufacturing time and material usage while maintaining dimensional accuracy and structural integrity.

Implementation Method 1

irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS12162063B2Additively manufactured interlocking casting core structure with ceramic shell

Publication Date: 2024.12.10 GENERAL ELECTRIC CO

AI summary

A method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and a second shell portion, wherein the first shell portion is adapted to interface with at least the second shell portion to form at least one first cavity between the core portion and the first and second shell portions. The core-shell mold may be inspected and assembled prior to connection of the wax gate component. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.