Integrated Ceramic Core-Shell Molds for Turbine Blade Cooling
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Solution Overview
Problem
Conventional methods for manufacturing complex turbine blades with intricate internal geometries, such as investment casting, are limited by the resolution capabilities of existing ceramic core-shell mold production techniques, which hinder the creation of fine detail features and efficient cooling hole patterns in the final product.
Innovation Solution
The use of direct light processing (DLP) to manufacture integrated ceramic core-shell molds with thin filaments connecting the core and shell portions, enabling the production of fine effusion cooling holes and eliminating the need for ball chutes and tip pins, by supporting the tip plenum core and allowing for more intricate cooling hole patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional investment casting methods are used to manufacture complex turbine blades, then the manufacturing process can produce components with intricate internal geometries, but the resolution capabilities of existing ceramic core-shell mold production techniques limit the creation of fine detail features and efficient cooling hole patterns
Solution Approach 1:
The patent merges the core and shell into an integrated core-shell mold structure where the core is formed within the shell as a single unified component. This integration eliminates the need for separate assembly steps and reduces the overall complexity of the mold system while maintaining the capability to produce fine detail cooling hole patterns through the combined structure.
Solution Approach 2:
The patent introduces thin filaments that extend in the third dimension between the core and shell portions, creating a spatial bridge that provides structural support without occupying significant volume. This dimensional approach allows the filaments to fulfill multiple functions (support, definition of cooling holes) while minimizing interference with the fine detail features being manufactured.
2Ease of manufacture
If traditional tip pins and ball chutes are used in ceramic core-shell molds, then the mold structure can support the tip plenum core, but additional post-casting modifications such as brazing are required
Solution Approach 1:
The patent extracts and eliminates the need for traditional tip pins and ball chutes by using thin filaments that are integrated directly into the core-shell structure. These filaments perform the support function without requiring separate components, thereby reducing the number of parts and eliminating post-casting modification steps such as brazing.
Solution Approach 2:
The thin filaments serve multiple functions simultaneously: they provide structural support for the tip plenum core, define the geometry of effusion cooling holes, and eliminate the need for separate tip pins and ball chutes. This multi-functionality reduces both the number of components and the complexity of post-casting operations.
3Productivity
If sufficient ceramic filaments are used between core and shell to locate and provide leaching pathways, then ball braze chutes can be eliminated, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines the functions of locating the core, providing leaching pathways, and eliminating ball braze chutes into a single integrated filament structure. The filaments are embedded within the core-shell mold during manufacturing, creating a unified structure that performs multiple functions simultaneously and improves manufacturing efficiency by eliminating separate operations.
4Manufacturing precision
If DLP manufacturing is used to create integrated ceramic core-shell molds with thin filaments, then fine effusion cooling holes can be produced, but the manufacturing process requires higher resolution capabilities
Solution Approach 1:
The patent utilizes DLP manufacturing technology which employs digital light processing with high resolution capabilities to create the thin filaments and fine cooling hole patterns. The process parameters (light resolution, layer thickness, filament dimensions) are optimized to achieve the desired manufacturing precision of effusion cooling holes while maintaining structural integrity of the core-shell mold.
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 approach enhances the resolution and precision of cooling hole patterns in cast components, supporting complex geometries and reducing post-casting modifications, enabling the production of turbine blades with improved cooling efficiency and reduced manufacturing complexity.
Implementation Method 1
direct light processing (DLP) to manufacture integrated ceramic core-shell molds
Implementation Method 2
chemical leaching in an alkaline bath
Data Source
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AI summary
The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade or stator vane, which provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.