Rapid Tooling for Gas Turbine Casting via Conductive Coating
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Solution Overview
Problem
The traditional manufacturing process for tooling used in investment casting, such as for gas turbine engine parts, is time-consuming, typically taking 8 to 28 weeks, which hinders the rapid production of complex geometries like internal cooling passages in airfoils and vanes.
Innovation Solution
A rapid manufacturing method utilizing stereolithography (SLA) or selective laser sintering (SLS) processes to create tooling from polymeric materials, followed by smoothing and coating with conductive metallic materials, allowing for the rapid production of casting articles in hours or days.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing processes (milling, high speed machining, EDM) are used to manufacture tooling, then manufacturing precision and durability are improved, but lead time increases to 8-28 weeks
Solution Approach 1:
A preliminary rapid prototype tooling is manufactured using stereolithography or selective laser sintering to enable immediate casting article production. This preliminary tooling allows the casting process to begin before the final precision tooling is complete, significantly reducing overall lead time while maintaining product quality
Solution Approach 2:
The tooling manufacturing process is segmented into two distinct phases: rapid prototype tooling manufacturing (using additive processes) and final precision tooling manufacturing (using traditional subtractive processes). This segmentation allows parallel execution of both processes, with the rapid prototype enabling immediate production while the precision tooling is being fabricated
2Strength
If traditional manufacturing processes are used, then tooling conductivity and strength are improved, but manufacturing speed decreases to hours or days
Solution Approach 1:
The rapid prototype tooling uses composite construction combining polymeric material (from stereolithography or selective laser sintering) with metallic coating layers. This composite structure provides sufficient strength for rapid prototyping while the metallic coating restores electrical conductivity and thermal properties needed for the casting process
Solution Approach 2:
The tooling material properties are changed through coating application - transforming the polymeric rapid prototype into a conductive, thermally stable tooling piece. The coating process modifies surface parameters (conductivity, hardness, thermal resistance) to match the requirements of the casting process without requiring bulk material changes
3Loss of time
If rapid manufacturing processes (stereolithography, selective laser sintering) are used, then lead time is reduced to hours or days, but manufacturing precision and surface quality worsen
Solution Approach 1:
Traditional mechanical finishing processes (milling, machining, grinding) are replaced with coating application processes. The coating is deposited onto the rapid prototype surface, providing the required precision and surface quality without requiring extensive post-processing of the additive manufactured part
Solution Approach 2:
The metallic coating acts as an intermediary layer between the rapid prototype and the casting article. This coating layer provides the necessary surface quality, dimensional accuracy, and functional properties (conductivity, thermal resistance) that the polymeric rapid prototype cannot provide alone, while requiring minimal post-processing
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 significantly reduces the lead time for manufacturing tooling, enabling the rapid production of complex casting articles with improved durability and conductivity, thus facilitating faster development of gas turbine engine components.
Implementation Method 1
The tooling is formed in a rapid manufacturing process from a polymeric material. In one example, the rapid manufacturing process is a stereolithography process.
Implementation Method 2
The rapid manufacturing method utilizing stereolithography (SLA) or selective laser sintering (SLS) processes to create tooling from polymeric materials
Implementation Method 3
followed by smoothing and coating with conductive metallic materials
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A rapid manufacturing method includes forming tooling (32) in a rapid manufacturing process. The tooling (32) is coated with a conductive material (44).