Hybrid Ceramic Metallic Casting Core for Gas Turbine Cooling
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Solution Overview
Problem
Current investment casting techniques face challenges in manufacturing fine, precisely located cooling passageways for gas turbine engine components, as they are difficult to manufacture and can be fragile, leading to inefficiencies in air cooling and reduced engine performance.
Innovation Solution
A casting core assembly comprising a metallic core with a thickened portion and a ceramic core, where the thickened portion is securely embedded within the ceramic core using adhesives or laminated sheets, allowing for precise cooling passageway formation and enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ceramic casting cores are used to form fine cooling passageways, then manufacturing precision of cooling features is improved, but the cores become fragile and difficult to manufacture
Solution Approach 1:
The patent applies composite materials by combining ceramic material with metallic material (such as tungsten, molybdenum, or nickel-based superalloy) to form a hybrid core structure. The ceramic portion provides the fine cooling passageway geometry with high precision, while the metallic portion embedded within or attached to the ceramic provides enhanced mechanical strength and structural integrity, resolving the contradiction between precision and fragility
Solution Approach 2:
The core is segmented into distinct ceramic and metallic portions, each optimized for its specific function. The ceramic section forms the intricate cooling passageways requiring high precision, while the separate metallic section provides structural support. This segmentation allows each material to perform its optimal function without compromising the other
2Use of energy by moving object
If fine cooling features are manufactured, then air cooling efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The complex fine cooling features are created by forming them in the core before casting, using the core itself as a negative mold or pattern. The ceramic and metallic materials are shaped to precisely replicate the desired cooling passageway geometry, allowing intricate features to be manufactured through forming processes rather than subsequent machining or complex assembly operations
3Temperature
If more cooling air is used, then cooling effectiveness is improved, but engine efficiency decreases
Solution Approach 1:
The core enables precisely located and sized cooling passageways that deliver cooling air exactly where needed in the casting. The fine features created by the high-precision core ensure efficient heat transfer at critical locations, maximizing cooling effectiveness with minimal cooling air consumption, thus improving engine efficiency by reducing the energy penalty of cooling air extraction
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 solution enables the creation of robust, finely detailed cooling passageways that improve air cooling efficiency in gas turbine engines, reducing the need for excessive cooling air and enhancing engine performance by maintaining structural integrity and reducing manufacturing complexities.
Implementation Method 1
a ceramic adhesive joint may be between the thickened portion and the ceramic core
Implementation Method 2
a metallic core having a thickened portion and a thin portion extending from the thickened portion
Data Source
AI summary
A casting core assembly (140) includes a metallic core (144, 146, 148; 360; 380; 400) and a ceramic core (142). A protuberant portion (184) of a metallic core is received in compartment (186) of the ceramic core.