Replaceable Inner Liner for Turbine Die Casting
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Solution Overview
Problem
The existing die cast systems for turbine airfoils are costly and inefficient due to the need for frequent reworking or replacement of hard steel core dies, which wear out quickly, leading to non-conforming castings and high expenses for maintaining accurate dimensions.
Innovation Solution
A die cast system with an inner liner insert that can be easily changed without reworking the die housing, allowing for the use of different materials for various parts of the liner to create intricate cooling systems, such as a non-ceramic, flexible material for the inner liner formed via selective laser melting, enabling cost savings and reduced production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hard steel core dies are used to form ceramic cores, then the core die can maintain structural integrity during high pressure injection, but the core die wears out quickly and requires expensive reworking or replacement
Solution Approach 1:
The core die is divided into two separate components: a durable hard steel housing that provides structural integrity and a replaceable inner liner that contacts the ceramic material. This segmentation allows the housing to be reused while only the inner liner needs replacement, resolving the contradiction between maintaining structural strength and extending service life.
Solution Approach 2:
The inner liner is designed as a consumable component that can be easily replaced when worn. By making the inner liner a separate, replaceable part rather than replacing the entire core die, the system reduces costs and downtime associated with die maintenance while the hard steel housing continues to provide long-term structural support.
2Manufacturing precision
If the entire die housing is reworked to change configuration, then accurate casting dimensions can be maintained, but the cost and time required increases significantly
Solution Approach 1:
The die system is segmented into a permanent housing and a replaceable inner liner. When configuration changes are needed, only the inner liner is replaced rather than reworking the entire die housing. This maintains casting dimension accuracy through precise liner manufacturing while significantly reducing the cost and complexity of manufacturing changes.
Solution Approach 2:
Different inner liners with various configurations are pre-manufactured to match specific casting requirements. When a configuration change is needed, the appropriate pre-made liner is simply swapped in, eliminating the need for expensive and time-consuming die reworking operations.
3Ease of manufacture
If a single material is used for the entire inner liner, then manufacturing is simpler, but intricate cooling systems cannot be created
Solution Approach 1:
The inner liner is divided into multiple sections or layers, each made from materials with different properties optimized for specific functions. For example, certain regions may use more compliant materials to form intricate cooling channels, while other regions use less compliant materials for structural support. This local differentiation enables complex cooling systems while maintaining manufacturing feasibility.
Solution Approach 2:
The inner liner is constructed as a composite structure combining different materials with complementary properties. This allows the liner to simultaneously provide structural integrity in some areas and flexibility for forming complex geometries in other areas, enabling intricate cooling systems without sacrificing manufacturing practicality.
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 costs and time by allowing for configuration changes without reworking the die, enabling the creation of complex cooling systems with more compliant materials, thus improving the efficiency and cost-effectiveness of the casting process.
Implementation Method 1
The inner liner may be formed via a selective laser melting process
Data Source
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AI summary
A die cast system (10) having an inner liner insert (12) that enables the configuration of a component (14) produced by the system to be easily changed by changing the inner liner insert (12) without having to rework the die housing (16) is disclosed. Because the inner liner insert (12) only need be removed and replaced to change the configuration of an outer surface of a component (14) produced by the system, the cost savings is significant in contrast with conventional systems in which the die would have to be reworked. The die cast system (10) may also include an inner liner (12) formed from first end and second end sub-inner liners (20, 22), whereby the first end sub-inner liner (20) may be from a first material that is less compliant than a material forming the second end sub-inner liner (22) enabling more intricate cooling systems to be created by the second end sub-inner liner (22).