Lost Core Molding Radial Tapering Cooling Passages
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Solution Overview
Problem
Existing methods for forming cooling passages in gas turbine airfoils using ceramic and refractory metal cores are limited, as ceramics struggle to create thin shapes and refractory metals are restricted in forming tapering passages, with previous combinations only allowing axial extension of refractory metals from ceramic cores.
Innovation Solution
A lost core assembly featuring a ceramic component with a tapered shape in the radial direction and a refractory metal component extending radially from the ceramic core, secured through slots and glue, allowing for the creation of thin, tapering passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If ceramic components are used to form cooling passages, then tapering passages can be formed, but thin shapes cannot be created
Solution Approach 1:
The core is divided into two distinct components: a ceramic component that provides the tapered shape, and a refractory metal component that extends radially to create thin sections. This segmentation allows each material to fulfill its strength - the ceramic provides tapering while the metal provides thinness.
Solution Approach 2:
The invention uses a composite core structure combining ceramic and refractory metal materials. The ceramic component (e.g., alumina, zirconia) provides heat resistance and tapering capability, while the refractory metal component (e.g., molybdenum, tungsten) provides thin-section capability and structural support, creating a material composite that achieves both tapering and thinness simultaneously.
2Length of moving object
If refractory metal components are used to form cooling passages, then thin shapes can be created, but tapering passages cannot be formed
Solution Approach 1:
The core is divided into two distinct components: a ceramic component that provides the tapered shape, and a refractory metal component that extends radially to create thin sections. This segmentation allows each material to fulfill its strength - the ceramic provides tapering while the metal provides thinness.
Solution Approach 2:
The invention uses a composite core structure combining ceramic and refractory metal materials. The ceramic component (e.g., alumina, zirconia) provides heat resistance and tapering capability, while the refractory metal component (e.g., molybdenum, tungsten) provides thin-section capability and structural support, creating a material composite that achieves both tapering and thinness simultaneously.
3Shape
If ceramic and refractory metal components are combined, then both tapering and thin shapes can be achieved, but the assembly complexity increases
Solution Approach 1:
The ceramic and refractory metal components are merged into a single integrated core assembly that functions as one unit during the molding process. The components are positioned and secured together (using adhesives, mechanical interlocking, or both) to form a unified structure that simplifies handling and injection molding, reducing operational complexity despite the multi-material composition.
Solution Approach 2:
An adhesive or bonding agent serves as an intermediary between the ceramic and refractory metal components, securely joining them together. This intermediary facilitates the connection between dissimilar materials with different thermal and mechanical properties, enabling the composite structure to function as a cohesive unit without requiring complex mechanical fastening systems.
4Ease of manufacture
If previous axial extension configuration is used, then assembly is simpler, but radial thin passages cannot be formed
Solution Approach 1:
The refractory metal component is repositioned from an axial extension (previous configuration) to a radial extension from the ceramic core. This dimensional change allows the metal component to extend perpendicular to the taper axis, enabling the formation of thin radial passages while maintaining the ceramic's tapering function. The radial configuration achieves thin-section capability in directions that axial extension cannot provide.
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
Enables the formation of efficient, thin, and tapering cooling passages within gas turbine engine components, enhancing cooling efficiency and structural integrity by combining the advantages of ceramic and refractory metal materials in a radial configuration.
Implementation Method 1
One method of forming the cooling passages is so-called lost core molding. In lost core molding, a core is formed and placed within a mold for forming the airfoil. Metal is injected into the mold and solidifies around the core. The core is then leached away leaving internal cavities within the airfoil.
Implementation Method 2
a glue is positioned in the slots to secure the refractory metal component to the ceramic component
Data Source
Figure 1~2B
Figure 3~4
AI summary
In a featured embodiment, a lost core assembly includes a ceramic component having a tapered shape in a radial direction. A refractory metal component extends radially from the ceramic core component. A method of molding a gas turbine engine component is also disclosed.