Integrated Core-Shell Casting Molds for Non-Linear Cooling Holes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing turbine blades with intricate internal geometries and cooling passages are limited by the resolution capabilities of existing core-shell mold production techniques, such as powder bed and selective laser activation, which hinder the formation of fine detail features and efficient cooling hole patterns.
Innovation Solution
The use of direct light processing (DLP) to create integrated ceramic filaments between the core and shell of the mold, allowing for the production of non-linear cooling holes with cross-sectional areas ranging from 0.01 to 2 mm², eliminating the need for ball chutes and tip pins, and enabling precise cooling hole patterns in turbine blades and stator vanes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional powder bed or selective laser activation methods are used to create core-shell molds, then the manufacturing process can be completed, but the resolution capability is insufficient to form fine detail features and efficient cooling hole patterns
Solution Approach 1:
The patent replaces conventional mechanical powder bed or selective laser activation methods with direct light processing (DLP) technology. The DLP system uses a digital light processor to project UV light patterns that cure liquid ceramic photopolymer resin layer by layer, enabling precise formation of cooling hole patterns and fine detail features without the resolution limitations of previous mechanical or laser-based methods.
Solution Approach 2:
The invention changes the fundamental processing parameters by using photopolymerization chemistry instead of thermal or mechanical processes. The liquid ceramic photopolymer resin undergoes chemical transformation when exposed to UV light, allowing for higher resolution feature formation. The cross-sectional area of cooling holes can be precisely controlled within the range of 0.01 to 2 mm² through parameter optimization of the DLP process.
2Reliability
If integrated ceramic filaments are used between core and shell to form cooling holes, then cooling efficiency is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the core and shell mold components with the cooling hole formation process into a single integrated structure. Ceramic filaments are embedded within the core-shell mold during the DLP manufacturing process itself, rather than being added separately. This integration allows the filaments to serve dual purposes: maintaining mold structural integrity and defining cooling hole pathways, thereby enhancing cooling efficiency without proportionally increasing manufacturing complexity.
Solution Approach 2:
The ceramic filaments act as intermediaries between the core and shell portions of the mold. These filaments provide both mechanical support to maintain the gap between core and shell, and serve as templates that will ultimately define the cooling hole geometry in the cast component. This intermediary role simplifies the overall process by combining support and feature formation functions.
3Reliability
If non-linear filament geometry is used to create non-linear cooling holes, then cooling efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent replaces conventional mechanical or laser-based additive manufacturing methods with direct light processing (DLP) technology. The DLP system uses a digital light processor to project precisely controlled UV light patterns that cure liquid ceramic photopolymer resin, enabling accurate formation of non-linear filament geometries with cross-sectional areas between 0.01 to 2 mm². This optical approach provides superior resolution and precision compared to previous mechanical or thermal methods.
Solution Approach 2:
The invention changes the fundamental processing parameters by using photopolymerization chemistry instead of thermal or mechanical processes. The liquid ceramic photopolymer resin undergoes chemical transformation when exposed to UV light, allowing for higher resolution feature formation. The cross-sectional area of cooling holes can be precisely controlled within the range of 0.01 to 2 mm² through parameter optimization of the DLP process.
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
DLP enables the production of turbine blades and stator vanes with non-linear cooling holes that enhance cooling efficiency and reduce the need for post-casting modifications, improving the manufacturing process by allowing for more complex internal geometries and efficient cooling systems.
Implementation Method 1
irradiating a portion of the liquid ceramic photopolymer adjacent to the cured portion through a window contacting the liquid ceramic photopolymer
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure generally relates to integrated core-shell investment casting molds that provide filament structures corresponding to cooling hole patterns in the surface of the turbine blade or stator vane, which provide a leaching pathway for the core portion after metal casting. These filament structures may be linear or non-linear. 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.