Hard Tool Configuration for Gas Turbine Core Flash Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing ceramic cores for gas turbine airfoils result in excessive flash during the casting process, leading to high cleanup costs and inefficiencies, especially with advanced features, due to the use of traditional mold forms and low-strength ceramic slurry that is prone to distortion and misalignment.
Innovation Solution
A hard tool configuration comprising a first and second platform with removable rake elements is used to create an internal mold geometry, allowing for precise shaping of the core with minimal to zero flash, where the rake elements define the detailed features and are easily removable, reducing post-process cleanup and improving geometric control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional mold forms with low-strength ceramic slurry are used, then the manufacturing process is simpler, but excessive flash is produced leading to high cleanup costs
Solution Approach 1:
The patent changes the physical-chemical parameters of the mold material by using high-strength ceramic slurry instead of traditional low-strength ceramic slurry. This parameter change enables the mold to maintain its shape and prevent flash during the casting process, thereby reducing flash removal costs while still being manufacturable.
Solution Approach 2:
The patent employs composite material structure in the mold design, combining high-strength ceramic slurry with specific mold configurations. This composite approach allows the mold to achieve both structural integrity to prevent flash and manufacturability, resolving the contradiction between ease of manufacture and flash loss.
2Device complexity
If traditional mold forms are used, then the device complexity is lower, but misalignment and distortion occur during the casting process
Solution Approach 1:
The patent changes the strength parameter of the ceramic slurry to high-strength formulation, which fundamentally improves the mold's ability to maintain geometric accuracy during casting. This parameter change prevents distortion and misalignment while keeping the overall mold structure relatively simple.
Solution Approach 2:
The patent segments the mold into multiple parts that can be assembled together, allowing each segment to be manufactured and positioned with high precision. This segmentation approach enables complex geometries to be achieved while maintaining manufacturing precision through controlled assembly of individual high-precision components.
3Device complexity
If manual cleanup methods are used for advanced features, then the equipment requirements are lower, but operator errors increase and productivity decreases
Solution Approach 1:
The patent implements a self-aligning mold design where the high-strength ceramic slurry inherently maintains proper alignment and prevents flash without requiring complex external alignment mechanisms or manual intervention during the casting process. This self-service capability eliminates operator errors and improves productivity while keeping equipment requirements relatively simple.
Solution Approach 2:
The patent replaces manual mechanical cleanup operations with a chemically enhanced ceramic slurry system that prevents flash and misalignment through its inherent material properties. This substitution eliminates the need for complex manual alignment procedures and increases productivity by reducing rework and operator errors.
Data Source
AI summary
A hard tool configuration and method of manufacturing advanced detailed trailing edge features in a core for casting. The hard tool configuration includes at least a first platform and a second platform. The hard tool configuration also includes a first end of a plurality of removable rake elements removably attached to at least one of the first platform and the second platform. The hard tool configuration also includes an internal mold geometry in a spacing in between the center facing side of the first platform and the center facing side of the second platform.