Additively Manufactured Ceramic Core-Shell Mold with Thin Filaments
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Solution Overview
Problem
Conventional methods for manufacturing ceramic core-shell molds lack the fine resolution capability to produce filaments of sufficiently small size and quantity for effusion cooling holes in turbine blades and stator vanes, limiting the complexity and efficiency of internal cooling systems in gas turbine engines.
Innovation Solution
The use of direct light processing (DLP) in additive manufacturing to create ceramic molds with thin filaments spanning between the core and shell portions, enabling the production of ceramic objects with precise cooling hole patterns and improving the structural integrity, thermal properties, and casting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods for manufacturing ceramic core-shell molds are used, then the manufacturing process is simple, but the resolution capability to produce fine filaments for cooling holes is insufficient
Solution Approach 1:
The patent replaces conventional mechanical manufacturing methods with direct light processing (DLP) additive manufacturing. The DLP system uses projected light patterns to selectively cure photopolymerizable ceramic material, enabling precise fabrication of thin filaments with diameters down to 10-100 micrometers. This optical-based approach achieves fine resolution capability (parameter_id: 29) that conventional mechanical methods cannot attain, while the automated layer-by-layer construction reduces manual intervention complexity.
Solution Approach 2:
The patent utilizes photopolymerizable ceramic materials with specific rheological properties that allow them to maintain shape after light exposure. By controlling the photopolymerization parameters (light intensity, exposure time, layer thickness) and material composition (ceramic particle size, resin viscosity), the process achieves fine filament resolution. The material transitions from liquid state during printing to solid state after curing, enabling precise dimensional control of cooling hole filaments.
2Reliability
If thin filaments are produced for effusion cooling holes, then the cooling efficiency of turbine blades is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The DLP additive manufacturing system replaces conventional drilling or wiring methods for creating cooling holes. The projected light pattern precisely defines filament locations and dimensions, with each filament corresponding to a specific cooling hole position. This optical approach achieves manufacturing precision (parameter_id: 29) sufficient for effusion cooling holes (10-100 micrometer diameter), enabling improved cooling efficiency (parameter_id: 27) through accurately positioned and sized cooling features.
Solution Approach 2:
The DLP system creates a digital model of the turbine blade with integrated cooling hole patterns, then directly fabricates the ceramic core-shell mold by selectively curing photopolymerizable material according to this digital design. The filament geometry and arrangement are copied from the digital model with high fidelity, ensuring that the manufactured filaments match the designed cooling hole specifications, thereby achieving both high cooling efficiency and manufacturing precision.
3Strength
If integrated core-shell molds with filaments are used, then the structural integrity of the mold is improved, but the manufacturing time increases
Solution Approach 1:
The patent merges the core and shell mold components into a single integrated structure fabricated in one additive manufacturing process. The photopolymerizable ceramic material is continuously deposited and cured to form both the core and shell portions with filaments connecting them, eliminating the need for separate manufacturing and assembly operations. This integration improves structural integrity (parameter_id: 14) by ensuring seamless bonding between core and shell, while the single-step fabrication reduces total manufacturing time compared to conventional multi-step processes.
Solution Approach 2:
The DLP process builds the integrated core-shell mold layer by layer from the bottom up, with filaments being formed simultaneously with the core and shell structures during the same fabrication process. This preliminary formation of connecting filaments ensures structural integrity is built-in during manufacturing rather than requiring post-assembly joining operations. The continuous fabrication process maintains productivity by avoiding interruptions for separate component assembly.
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
DLP allows for the creation of ceramic molds with fine filaments that produce turbine blades with intricate cooling hole patterns, enhancing cooling efficiency and reducing manufacturing time and material usage, while also improving the structural and thermal properties of the mold.
Implementation Method 1
contacting a cured portion of a workpiece with a liquid ceramic photopolymer; irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer
Data Source
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 filter, first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may manufactured using an additive manufacturing process and may include an integrated ceramic filter. 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.