Porous Ceramic Casting Element via Stereolithography
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Solution Overview
Problem
Current methods for fabricating complex gas turbine components, such as turbine blades with intricate cooling circuits, require multi-step processes involving wax dies and external ceramic shell coating, which are time-consuming and inefficient.
Innovation Solution
A ceramic resin is used, comprising a crosslinkable precursor, photoinitiator, ceramic particles, and pore-forming particles, which is formed through additive manufacturing processes like stereolithography to create a single-piece sacrificial ceramic casting element with controlled porosity, reducing the need for multiple core components and simplifying the casting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional investment casting process with wax injection and external ceramic shell coating is used, then complex turbine blade components can be formed, but the process cycle time is excessive and manufacturing efficiency is low
Solution Approach 1:
The patent combines the ceramic core and external ceramic shell into a single integrated ceramic casting element formed by stereolithography. This eliminates the separate steps of wax injection, external shell coating, and core assembly, reducing process cycle time while maintaining the ability to form complex turbine blade geometries with internal cooling passages.
Solution Approach 2:
The patent replaces the mechanical multi-step investment casting process (wax injection, shell coating, assembly) with an additive manufacturing process (stereolithography) that directly forms the complete ceramic casting element in a single operation, significantly reducing manufacturing time.
2Strength
If dense ceramic parts are produced by current stereolithography materials, then structural integrity is achieved, but leaching time becomes excessive due to lack of porosity
Solution Approach 1:
The patent incorporates pore-forming particles into the stereolithography resin formulation. When the resin is cured and subsequently fired, these particles burn out leaving controlled porosity within the ceramic structure. This porosity provides channels for rapid leaching of the ceramic core material while maintaining sufficient structural integrity for casting applications.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the stereolithography resin by adding pore-forming agents and adjusting the ceramic particle composition. These parameter changes enable the resin to form a ceramic structure with optimized porosity that balances structural strength with rapid leaching capability.
3Manufacturing precision
If multiple core components are used in conventional casting, then complex internal cooling circuits can be formed, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges multiple separate core components into a single integrated ceramic casting element formed by stereolithography. The additive manufacturing process can directly create complex internal geometries including cooling circuits, impingement channels, and support structures within one monolithic component, eliminating the need for assembling multiple pieces.
Solution Approach 2:
The patent utilizes the three-dimensional capabilities of stereolithography to create complex internal geometries that would be difficult or impossible to achieve with conventional multi-piece assembly. The layer-by-layer additive process allows intricate cooling circuits and internal passages to be formed directly within the ceramic structure.
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 enables the rapid production of high-complexity ceramic cores with controlled porosity, reducing the overall process cycle time and eliminating the need for wax injection and external ceramic shell coating, resulting in cost and time savings while maintaining high-quality castings.
Implementation Method 1
applying light onto the ceramic resin such that the photoinitiator initiates polymerization of the crosslinkable precursor to form a crosslinked polymeric matrix
Implementation Method 2
heating the crosslinked polymeric matrix to a first temperature to burn out the pore forming particles
Data Source
AI summary
A ceramic resin is provided, along with its methods of formation and use. The ceramic resin may include a crosslinkable precursor, a photoinitiator, ceramic particles, and pore forming particles. The ceramic resin may be utilized to form a ceramic casting element, such as via a method that includes forming a layer of the ceramic resin; applying light onto the ceramic resin such that the photoinitiator initiates polymerization of the crosslinkable precursor to form a crosslinked polymeric matrix setting the ceramic particles and the pore forming particles; and thereafter, heating the crosslinked polymeric matrix to a first temperature to burn out the pore forming particles.