3D Printed Sand Core for Turbine Diaphragm Vane Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current casting techniques for diaphragms in steam turbines and gas turbines lack precision in vane positioning and orientation, leading to deviations in vane throat area and reduced energy transfer efficiency.
Innovation Solution
A method involving a digital representation of a sand core created through three-dimensional printing, with preformed vanes inserted into cavities and high-temperature putty applied to prevent metal leakage, allowing for precise alignment and casting within a mold filled with liquid metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional casting patterns and core construction tools are used to position vanes, then the manufacturing process is simple, but the location and orientation precision of vanes deteriorates
Solution Approach 1:
The patent applies 3D printing technology to create sand cores with precisely controlled geometric parameters for vane positioning. The digital modeling and layer-by-layer deposition process enables exact control of vane location and orientation parameters, resolving the precision issue while the software-driven process manages the complexity of core construction.
Solution Approach 2:
The patent replaces traditional mechanical core construction tools and manual positioning methods with a digital 3D printing system. The binder jetting process substitutes mechanical assembly with automated material deposition controlled by digital models, achieving superior precision while reducing manual intervention and tool complexity.
2Productivity
If traditional diafram core building techniques are used, then the manufacturing process is simple, but the production time increases and surface finish deteriorates
Solution Approach 1:
The 3D printing process enables continuous layer-by-layer construction of sand cores without interruption, eliminating the sequential steps of traditional core building. This continuous deposition process reduces production time while the automated nature of the printer manages process complexity, and the resulting smooth layers improve endwall surface finish.
3Manufacturing precision
If preformed vanes are welded into rings, then the manufacturing process is simple, but the vane position and orientation precision deteriorates
Solution Approach 1:
The patent creates pre-formed sand core cavities with exact vane positioning before the casting process. The 3D printed sand core includes precisely shaped cavities that guide vanes into correct positions and orientations during assembly, ensuring accurate vane throat areas. This preliminary preparation of the molding cavity simplifies the overall manufacturing process by integrating positioning functionality into the core itself.
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 precision in vane orientation and reduces production time, improving endwall surface quality and predicting turbine performance more accurately.
Implementation Method 1
a three-dimensional component can be created by bonding together successive layers of a porous material with droplets of a binder material
Implementation Method 2
bonding together successive layers of sand with droplets of a binder material
Implementation Method 3
the casting mold is filled with liquid metal. After the liquid metal has solidified and cooled
Data Source
AI summary
A method for casting a diafram having inner and outer rings with preformed vanes circumferentially spaced therebetween is disclosed. A digital representation of a sand core is created. Based on this digital representation, a sand core is produced by bonding together successive layers of sand with droplets of a binder material using a binder printhead having nozzles for supplying jets of binder material droplets. A plurality of vanes is inserted into the cavities of the sand core. The sand core is then placed into a casting mold and filled with liquid metal. After the liquid metal has solidified and cooled, the sand core and any remaining sand is removed from the cast diafram.