Grouped Grain Casting with Shield and Scepter
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current cast article technologies are limited by the inability to create structures with multiple grain patterns in a single cast, restricting the utilization of diverse properties in design applications.
Innovation Solution
A method and system for forming articles with distinct grain patterns in different portions, such as an equiaxed grain pattern in the root attachment section and a directionally solidified pattern in the airfoil portion, using a mold with a shield and a programmable scepter to control grain formation, and applying cobalt-containing materials for enhanced grain growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single grain pattern is used in a cast structure, then the manufacturing process is simple, but the design flexibility and property optimization are limited
Solution Approach 1:
The cast structure is divided into multiple zones with different grain patterns. A shield is placed within the mold to segment the casting area, allowing the first portion to develop one grain pattern while the second portion develops a different grain pattern. This segmentation enables different mechanical properties in different regions of the same component.
Solution Approach 2:
Different grain patterns are created in different regions of the cast structure to optimize local properties. The first portion may have an equiaxed grain structure suitable for certain mechanical loads, while the second portion has a directionally solidified structure optimized for other requirements. This local quality approach allows tailoring properties to specific functional needs.
2Adaptability or versatility
If multiple grain patterns are created in a single cast, then design capabilities are enhanced, but the manufacturing complexity increases
Solution Approach 1:
A shield is introduced as an intermediary element within the mold to facilitate the creation of multiple grain patterns. The shield acts as a physical barrier that influences heat flow and solidification patterns, enabling different grain structures to form in different portions of the casting without requiring separate casting operations.
Solution Approach 2:
The solidification parameters are changed spatially within the mold to produce different grain patterns. By controlling temperature gradients, cooling rates, and solidification direction in different regions, the process creates equiaxed grains in one portion and directionally solidified grains in another portion, optimizing properties for different functional requirements.
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 creation of turbine engine components with optimized transverse and radial properties by allowing multiple grain patterns in a single cast, enhancing design capabilities and performance.
Implementation Method 1
applying a cobalt containing material to a surface of said wax pattern prior to said dipping step
Implementation Method 2
placing a shield around the mold. The shield placing step may comprise placing a shield which extends from a first region of the mold where a root attachment section will be formed to a second region of the mold where a platform will be formed
Implementation Method 3
providing a scepter and a controller for the scepter; programming the controller to have a grouped grain program profile; and powering the scepter after the metal material in molten form has been placed into the mold
Data Source
AI summary
A method for forming an article includes providing a mold and casting a metal material within the mold so that a part is produced which has a first portion having a first grain pattern and a second portion having a second grain pattern different from said first grain pattern.