Jacketed Mold Pattern for Turbine Component Casting
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Solution Overview
Problem
Existing casting methods face challenges in producing intricate near-net shaped components with precise outer surface features, as known patterns and cores are fragile and expensive, and machining processes are time-consuming and costly, especially for components like hot gas path components in gas turbines.
Innovation Solution
A method involving forming a jacket around a precursor component to create a jacketed precursor component, which is then used to fabricate a mold, allowing for the casting of components with intricate shapes and features, where the jacket material is either absorbed or remains intact within the component, defining the outer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional patterns and cores are used to define intricate component shapes, then manufacturing precision can be achieved, but the patterns become fragile and expensive to produce and handle
Solution Approach 1:
The patent uses a digital model as a copy of the desired component geometry to generate toolpaths for machining the pattern. This digital copy allows for precise reproduction of intricate features without the fragility of physical patterns. The digital model can be stored and reused indefinitely without degradation, eliminating handling risks while maintaining manufacturing precision through computer-controlled machining processes.
2Manufacturing precision
If intricate near-net shaped components are produced through casting with precise patterns, then manufacturing precision is improved, but the complexity of producing and handling patterns increases
Solution Approach 1:
The patent replaces the mechanical system of physical pattern fabrication and handling with a computer-controlled machining system. Instead of manually creating and handling complex physical patterns, the invention uses digital models and automated CNC machining to produce patterns with intricate geometries. This substitution eliminates the complexity of manual pattern production while maintaining high precision through programmable control.
3Manufacturing precision
If components are formed by drilling and machining to obtain final shape, then manufacturing precision can be achieved, but production time and costs increase
Solution Approach 1:
The patent applies preliminary action by creating a near-net shaped component through investment casting before final machining. The pattern is used to form a mold cavity that produces a cast component close to the final geometry, requiring minimal subsequent machining. This preliminary shaping action significantly reduces the amount of material removal needed and decreases production time compared to forming the complete final shape through machining alone.
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 precision and repeatability in forming components with intricate structures, reduces the risk of damage during handling and processing, and decreases production time and costs by enabling the creation of components that cannot be accurately formed using traditional methods.
Implementation Method 1
A molten metal alloy is introduced to the cavity of the mold, and in some methods, around a ceramic core, and cooled to form the component
Data Source
AI summary
A method of forming a component includes coupling a jacket around at least a portion of a precursor component to form a jacketed precursor component. The jacket is shaped to correspond to a net shape of an outer surface of the component. A mold is formed around the jacketed precursor component. A component material in a fluid state is introduced into a jacketed cavity defined in the mold to form the component. The jacketed cavity is defined in a space at least partially created by removal of the precursor component from the jacketed precursor component.