Monocrystalline Seed Production via Integrated Wax Pattern Casting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing process of monocrystalline parts with specific crystallographic orientations is complex and costly, particularly in achieving both primary and secondary orientations, which is essential for high-pressure distributors in turbomachines.
Innovation Solution
A method to manufacture monocrystalline seeds with integrated crystalline orientation control, where a wax model comprising a part, starter seed, and metal casting feeds is used, allowing for directed solidification and subsequent separation of raw seeds with controlled crystallographic structure, eliminating the need for separate seed production and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate seed production process is used, then crystallographic orientation control is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the seed production process with the main part casting process by integrating a seed model into the wax pattern. The seed model is positioned within the wax pattern during injection molding, and both are cast together in a single operation, eliminating the need for separate seed production facilities and reducing manufacturing complexity while maintaining crystallographic orientation control.
Solution Approach 2:
The wax pattern serves multiple functions: it forms the final part geometry and simultaneously provides the seed model structure. The seed model is created as an integral part of the wax pattern, allowing the same molding process to produce both the part and the seed, thereby reducing the number of specialized processes required.
2Manufacturing precision
If separate seed production is performed, then starter seeds with correct orientation are obtained, but production time increases
Solution Approach 1:
The seed model is pre-positioned within the wax pattern before the main casting process. The orientation of the seed model is established during the wax injection molding stage, so that when the metal is cast and solidifies, the crystallographic orientation is already determined. This preliminary positioning eliminates the need for separate seed production and orientation adjustment steps.
Solution Approach 2:
The patent merges the seed production timeline with the main part casting timeline. Both processes occur simultaneously in a single casting operation, reducing the total production cycle time while ensuring the seed achieves the correct crystallographic orientation through the integrated mold design.
3Stability of the object's composition
If traditional seed manufacturing is used, then monocrystalline structure is achieved, but manufacturing cost increases
Solution Approach 1:
The patent combines two previously separate manufacturing operations (seed production and part casting) into a single integrated process. The seed model is embedded in the wax pattern, and both are cast together in one operation, reducing the number of facility requirements, labor steps, and overhead costs associated with maintaining separate seed production capabilities.
Solution Approach 2:
The wax pattern itself serves as the mold for creating the seed model. The structural features of the wax pattern directly define the seed geometry and orientation, eliminating the need for separate seed production tooling and reducing manufacturing costs while maintaining the monocrystalline structure through controlled solidification.
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 simplifies the production of monocrystalline seeds, reduces overall costs, and enables parallel finishing operations with radiocrystallographic control, thereby shortening the manufacturing cycle and lowering production expenses.
Implementation Method 1
solidification is carried out from a starter seed
Implementation Method 2
directed solidification of the metal is carried out in the mold
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Producing monocrystalline seeds for use as starter seeds in the manufacture of high pressure turbine distributors comprises making a wax model comprising a model of the distributor, a starter seed model and a crude seed model, forming a ceramic mold from the wax model, incorporating a starter seed into the mold, pouring metal into the mold, effecting directed solidification of the metal from the starter seed so that the resulting crude seed has the same crystallographic structre as the casting, and separating the crude seed from the casting for subsequent use as a starter seed. Producing monocrystalline seeds for use as starter seeds in the manufacture of high pressure turbine distributors comprises making a wax model comprising a model of the distributor, a starter seed model with a crystallographic orientation plane and a crude seed model with a crystallographic orientation plane, forming a ceramic mold from the wax model, incorporating a starter seed into the mold, pouring metal into the mold, effecting directed solidification of the metal from the starter seed so that the resulting crude seed has the same crystallographic structre as the casting, and separating the crude seed from the casting for subsequent use as a starter seed.