Integral Core Bumpers for Precise Ceramic Airfoil Casting

Solution Overview

Problem

The high thermal loads in next-generation turbofan engines due to higher operating temperatures and pressure ratios lead to reduced operational life of components, and existing methods for inserting metal apparatuses into ceramic cores for airfoils are inefficient and prone to manual errors.

Innovation Solution

A casting core assembly with an integral bumper and metal apparatus, such as a pin or sphere, is integrated into the ceramic core, coupled via adhesive or mechanical lock, eliminating manual insertion and ensuring repeatable positioning, thus enhancing thermal stability and reducing stress concentrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual insertion methods are used for metal apparatuses into ceramic cores, then flexibility in positioning is maintained, but manufacturing precision and repeatability deteriorate due to manual errors

Engineering Contradiction:

Improvepositioning precisionVSAvoidintegration complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The bumper and metal apparatus are merged into a single integral component during ceramic core manufacturing. The metal apparatus is embedded within the bumper structure, eliminating the need for separate insertion steps and ensuring precise, repeatable positioning without manual intervention.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The metal apparatus is positioned and secured within the bumper before the ceramic core manufacturing process is completed. This preliminary positioning ensures that the metal apparatus is precisely located before the core is used in airfoil production, eliminating positioning errors that would occur with manual insertion later.

Inventive Principle:

Principle #10Preliminary action

2Stability of the object's composition

If holes are left in the ceramic core for metal apparatus insertion, then ease of assembly is maintained, but stress concentrations increase and thermal stability deteriorates

Engineering Contradiction:

Improvethermal stabilityVSAvoidassembly ease

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The bumper and metal apparatus are merged into a single integral component during ceramic core manufacturing. The metal apparatus is embedded within the bumper structure, eliminating the need for separate insertion steps and ensuring precise, repeatable positioning without manual intervention.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The problematic holes that would be required for manual insertion are completely eliminated. The metal apparatus is fully integrated into the bumper structure, removing the source of stress concentrations and thermal instability that would arise from holes in the ceramic core.

Inventive Principle:

Principle #2Taking out (Extraction)

3Productivity

If existing methods are used for inserting metal apparatuses, then process simplicity is maintained, but productivity deteriorates due to inefficiency and manual errors

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidintegration complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The bumper and metal apparatus are merged into a single integral component during ceramic core manufacturing. The metal apparatus is embedded within the bumper structure, eliminating the need for separate insertion steps and ensuring precise, repeatable positioning without manual intervention.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The metal apparatus is positioned and secured within the bumper before the ceramic core manufacturing process is completed. This preliminary positioning ensures that the metal apparatus is precisely located before the core is used in airfoil production, eliminating positioning errors that would occur with manual insertion later.

Inventive Principle:

Principle #10Preliminary action

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

The solution provides improved thermal stability and reduces stress concentrations, extending the operational life of airfoil components by allowing precise positioning and eliminating holes during casting.

Implementation Method 1

The metal apparatus may be coupled to the bumper by at least one of an adhesive or a mechanical lock

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

The metal apparatus may be coupled to the bumper by at least one of an adhesive or a mechanical lock

Methodology Applied

Scientific EffectMechanical fastening: Mechanical Fastener

Data Source

PatentUS12358043B2Integral core bumpers

Publication Date: 2025.07.15 RTX CORP

AI summary

A casting core assembly is disclosed herein. The casting core assembly comprises a casting core and a bumper assembly. The bumper assembly is disposed on an outer surface of the casting core. The bumper assembly comprises a receptacle and a metal apparatus. The metal apparatus may be a pin, a sphere, or the like.