Refractory Metal Core Assembly Adhesive Removal
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Solution Overview
Problem
State-of-the-art refractory metal core cooling circuits in turbine engine components often contain defects and artifacts due to incomplete removal of adhesive material, which reduces cooling effectiveness and compromises component strength.
Innovation Solution
A method involving a core assembly with a ceramic core element and refractory metal core, where the refractory metal core is secured with an adhesive, and surplus adhesive is removed from both sides using access paths provided by the core assembly, ensuring complete adhesive removal and preventing unwanted artifacts during investment casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive material is used to secure the refractory metal core into the ceramic core, then the refractory metal core is firmly fixed in position, but surplus adhesive remains on the refractory metal core causing defects and artifacts
Solution Approach 1:
The patent applies the extraction principle by providing access paths that enable the removal of surplus adhesive material from the refractory metal core. The access paths allow tools to reach and extract the harmful adhesive residues from the sides of the refractory metal core that would otherwise remain trapped and cause defects in the final casting.
2Reliability
If the refractory metal core is positioned deep within the ceramic core for optimal cooling, then cooling effectiveness is improved, but access for adhesive removal becomes difficult
Solution Approach 1:
The patent applies the dimensionality change principle by creating access paths that extend through the ceramic core structure. These access paths provide a new dimensional route (through the ceramic core walls) to reach the refractory metal core, enabling adhesive removal without requiring direct lateral access that would compromise the deep positioning of the core for optimal cooling.
3Strength
If adhesive is applied generously to ensure complete bonding, then the refractory metal core is securely attached, but more surplus adhesive remains requiring removal
Solution Approach 1:
The patent applies the preliminary action principle by providing access paths during the core assembly stage, before the final casting process. This allows adhesive removal to be performed as a preliminary step, making the process simpler and more effective rather than attempting removal after casting when access would be even more restricted.
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 enhances the effectiveness of internal cooling circuits by eliminating defects and artifacts, thereby improving the strength and cooling performance of turbine engine components.
Implementation Method 1
securing a first end of the refractory metal core into a slot of the ceramic core with an adhesive
Data Source
AI summary
A core assembly for forming a cast component includes a refractory metal core and a ceramic core element. The refractory metal core includes first and second ends and sides extending from the first end to the second end. The ceramic core element includes a slot positioned between first and second lands, each land having an inner surface facing the slot and an adjacent outer surface. The first end of the refractory metal core is secured within the slot with an adhesive, and the refractory metal core extends from the ceramic core element in both a longitudinal and a transverse direction. The slot, lands, and refractory metal core form a core assembly providing access paths to the sides of the refractory metal core. Surplus adhesive is removed from the refractory metal core via the access paths. Investment casting provides the component with an internal passage and an internal cooling circuit.