DLP Ceramic Core-Shell Molds for Turbine Cooling Filaments

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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 restricts the creation of intricate cooling hole patterns and increases manufacturing time and expense due to the resolution limitations of powder bed and selective laser sintering processes.

Innovation Solution

The use of direct light processing (DLP) to fabricate ceramic casting molds with integrated filaments that span between the core and shell portions, enabling the production of thin filaments for effusion cooling holes and improving the structural integrity, thermal properties, and efficiency of the casting process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If powder bed or selective laser sintering processes are used to manufacture ceramic molds, then the manufacturing process can be automated, but the resolution limitations prevent production of fine filaments for intricate cooling hole patterns

Engineering Contradiction:

Improveautomation of manufacturing processVSAvoidresolution for fine filament production

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The patent replaces mechanical sintering processes (selective laser sintering, powder bed) with a photopolymerization-based DLP system. This substitution enables higher resolution filament production while maintaining automation, as the DLP process uses light to cure liquid resin layer-by-layer with greater precision than thermal sintering methods can achieve.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional investment casting methods are used, then the manufacturing process is well-established, but manufacturing time and expense increase due to inability to produce fine filaments

Engineering Contradiction:

Improveestablished manufacturing processVSAvoidmanufacturing time and expense

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent changes the fundamental manufacturing parameters by transitioning from thermal sintering to photopolymerization curing. This parameter change allows for finer feature resolution and reduced manufacturing time, while the DLP process maintains ease of manufacture through automated, computer-controlled operation similar to conventional investment casting workflows.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If DLP is used to fabricate ceramic molds with integrated filaments, then fine filaments for effusion cooling holes can be produced, but the process is newer and less established than conventional methods

Engineering Contradiction:

Improvefine filament production capabilityVSAvoidestablishment of manufacturing process

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent segments the manufacturing process into distinct stages: DLP fabrication of the ceramic mold with integrated filaments, followed by traditional investment casting steps. This segmentation allows the innovative DLP process to address the critical resolution issue while relying on well-established conventional processes for the remaining manufacturing steps, thereby reducing overall process risk.

Inventive Principle:

Principle #1Segmentation

4Strength

If integrated filaments are incorporated into the core-shell mold structure, then structural integrity and thermal properties improve, but the device complexity increases

Engineering Contradiction:

Improvestructural integrity of moldVSAvoidcomplexity of integrated core-shell structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the support structure function with the cooling hole pattern function by integrating filaments directly into the core-shell mold structure during DLP fabrication. This consolidation eliminates the need for separate support structures and cooling hole creation steps, thereby improving structural integrity while actually reducing overall process complexity despite the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

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 turbine blades with complex cooling hole patterns not previously attainable, reducing manufacturing time and material usage while enhancing the structural and thermal properties of the cast components.

Implementation Method 1

direct light processing (DLP) to fabricate ceramic casting molds

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Data Source

PatentUS11235491B2Additively manufactured integrated casting core structure with ceramic shell

Publication Date: 2022.02.01 GENERAL ELECTRIC CO

AI summary

Integrated core-shell investment casting molds include a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud.