Ceramic Core-Shell Mold with Thin Filaments for Turbine Cooling

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Solution Overview

Problem

Conventional methods for manufacturing turbine blades and stator vanes using investment casting face limitations in producing fine filaments between the core and shell of the mold, which restrict the creation of intricate cooling hole patterns and increase manufacturing time and expense due to resolution limitations in powder bed and selective laser sintering processes.

Innovation Solution

The use of direct light processing (DLP) for additive manufacturing allows for the production of ceramic core-shell molds with thin filaments spanning the core and shell, enabling the creation of fine cooling holes and reducing the need for post-casting modifications like drilling, by exposing the entire length of the filament between the window and the build plate, thus overcoming resolution constraints of traditional methods.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If powder bed or selective laser sintering processes are used for additive manufacturing of ceramic molds, then the manufacturing capability is improved, but the resolution limitation prevents production of fine filaments and increases manufacturing time

Engineering Contradiction:

Improveresolution capabilityVSAvoidmanufacturing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces conventional powder bed or selective laser sintering processes with direct light processing (DLP) additive manufacturing. This substitution enables the production of fine filaments with superior resolution by using a digital light processing system that cures photopolymerizable ceramic material layer by layer through a digital micromirror device, achieving manufacturing precision that was not attainable with previous mechanical or laser-based sintering methods while maintaining efficient production rates

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Device complexity

If conventional additive manufacturing methods are used, then the manufacturing process is simplified, but the resolution constraints prevent creation of intricate cooling hole patterns

Engineering Contradiction:

Improveprocess simplicityVSAvoidcooling hole pattern precision

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent changes the key processing parameter from laser-based or powder bed sintering to digital light processing with photopolymerization. This parameter change enables the system to produce fine filaments with precise dimensions and complex geometries required for intricate cooling hole patterns, while the additive manufacturing approach maintains process simplicity by building the mold layer by layer from a digital model without requiring complex tooling or multiple manufacturing steps

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If thin filaments are produced using traditional methods, then the manufacturing capability is maintained, but the resolution limitations restrict the creation of fine cooling holes

Engineering Contradiction:

Improvecooling hole sizeVSAvoidmanufacturing capability

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent substitutes traditional powder bed or laser sintering manufacturing methods with direct light processing additive manufacturing. This replacement enables the production of thin filaments with precisely controlled dimensions that can create fine cooling holes, while the digital light curing process maintains ease of manufacture by using a straightforward layer-by-layer building approach with photopolymerizable ceramic material that cures upon exposure to projected light patterns

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enables the production of turbine blades with complex cooling hole patterns not previously attainable, reducing manufacturing time and costs by directly forming precise cooling holes within the casting process, and allowing for improved thermal management and structural integrity.

Implementation Method 1

direct light processing (DLP) for additive manufacturing allows for the production of ceramic core-shell molds with thin filaments spanning the core and shell, enabling the creation of fine cooling holes and reducing the need for post-casting modifications like drilling, by exposing the entire length of the filament between the window and the build plate

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Data Source

PatentUS11529672B2Additively manufactured casting core-shell mold with integrated filter and ceramic shell

Publication Date: 2022.12.20 GENERAL ELECTRIC CO

AI summary

A method of forming a cast component and a method of forming a casting mold is described herein. The ceramic core-shell mold includes at least 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 be 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.