Lattice Structure Mold Core Positioning
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Solution Overview
Problem
Existing methods for forming components with internal passages, such as in gas turbines, face challenges with precise core positioning, fragility of ceramic cores, and time-consuming drilling processes, leading to decreased yield and increased costs.
Innovation Solution
A lattice structure is selectively positioned within a mold cavity, with a channel defined through it to receive a core, allowing the core to be formed from a material that is absorbable by the component material, eliminating the need for core removal and enabling precise positioning and support for complex internal passage shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a ceramic core is used to define the internal passage, then the internal passage can be formed in the component, but the core is fragile and difficult to position precisely
Solution Approach 1:
The patent uses a composite core structure consisting of a ceramic core material surrounded by a refractory material layer. This composite construction provides the ceramic's ability to define the internal passage geometry while the refractory material provides enhanced strength and resistance to thermal shock, resolving the contradiction between positioning precision and structural strength.
Solution Approach 2:
The patent employs preliminary positioning features such as pins, ribs, or grooves formed in the mold cavity before the casting process. These pre-formed features mechanically constrain the core in precise positions, eliminating positioning errors and ensuring repeatable internal passage locations without requiring the core itself to be rigid enough for precise positioning.
2Ease of manufacture
If a ceramic core is used to define the internal passage, then the internal passage can be formed, but the core is difficult and expensive to produce and handle without damage
Solution Approach 1:
By creating a composite core with a refractory material shell surrounding the ceramic core, the patent makes the core easier to handle and less prone to damage during production and casting. The refractory material provides a protective barrier that prevents the fragile ceramic from breaking during handling, mold assembly, and the casting process, while still allowing the ceramic to perform its function of defining the internal passage.
Solution Approach 2:
The patent treats the core as a disposable element that is left in the mold cavity during casting and then removed after the component is formed. This approach eliminates the need for expensive and complex core recovery processes, and the core can be easily replaced for the next casting cycle, improving manufacturing efficiency and reducing costs associated with core maintenance and repair.
3Productivity
If drilling is used to form the internal passage in a subsequent process, then the internal passage can be created, but the process is time-consuming and expensive
Solution Approach 1:
The patent forms the internal passage during the initial casting process by incorporating a core into the mold cavity before pouring the molten material. This preliminary action eliminates the need for subsequent drilling or machining operations to create the internal passage, significantly reducing production time and manufacturing complexity while maintaining the ability to create complex curved passages that would be difficult to drill.
Solution Approach 2:
The patent merges the internal passage formation operation with the main casting process by using a core that is positioned in the mold cavity and remains in place during casting. This combines two separate operations (casting and internal passage creation) into a single simultaneous process, improving productivity by eliminating sequential steps and reducing overall manufacturing time and cost.
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 method reduces fragility issues, allows for the use of more complex core designs, and decreases the time and cost associated with core handling and mold preparation, while ensuring the structural integrity and performance of the component.
Implementation Method 1
The lattice structure is formed from a first material selected to be absorbable by a component material introduced into the mold cavity to form the component
Data Source
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AI summary
A mold assembly (301) for use in forming a component having an internal passage defined therein is provided. The component is formed from a component material. The mold assembly includes a mold (300) that defines a mold cavity (304) therein. The mold assembly also includes a lattice structure (340) selectively positioned at least partially within the mold cavity. The lattice structure is formed from a first material (322) that is at least partially absorbable by the component material in a molten state. A channel (344) is defined through the lattice structure, and a core (324) is positioned in the channel such that at least a portion (315) of the core extends within the mold cavity and defines the internal passage when the component is formed in the mold assembly.