Segmented Aerofoil Casting for Core Support and Cooling Passage
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Solution Overview
Problem
The existing methods for manufacturing aerofoils for gas turbine engines face challenges in efficiently casting vanes that require high-temperature resistance and cooling, often resulting in complex core support issues and potential weak points from core removal during the casting process.
Innovation Solution
A method involving casting two separate body portions of an aerofoil, where one portion forms the cooling passage and the other closes the opening at the leading edge, simplifying core support and allowing for improved aerodynamic efficiency by forming a slot at the trailing edge, which can be made thinner and better controlled, and enabling efficient cooling fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a core is used to form an internal passage in a casting process, then the passage can be created, but unwanted openings and weak points are introduced where the core was supported
Solution Approach 1:
The aerofoil is divided into two separate body portions that are cast independently and then joined. The first body portion contains the internal passage formed by a core, while the second body portion closes the opening at the leading edge. This segmentation allows the core to be supported at the trailing edge only, eliminating unwanted openings and weak points while maintaining passage integrity.
Solution Approach 2:
The core is completely removed after casting the first body portion, and the opening it created is closed by bonding the second body portion. This extraction eliminates the harmful effect of core support openings while preserving the beneficial internal passage structure.
2Ease of manufacture
If the core is supported from its edges during casting, then the casting process can proceed, but artefacts or weak points remain in the cast part
Solution Approach 1:
By segmenting the aerofoil into two body portions, the core support structure is simplified to edge-only support at the trailing edge. The second body portion is then bonded to close the leading edge opening, removing artefacts and weak points while maintaining manufacturing simplicity.
3Productivity
If a slot is formed at the trailing edge, then aerodynamic efficiency is improved, but precise control of slot thickness and positioning is difficult
Solution Approach 1:
The slot is formed as a feature of the first body portion during casting, with precise thickness and positioning controlled by the core geometry and casting process. The second body portion is then bonded to close the leading edge, preserving the precisely controlled slot dimensions while maintaining aerodynamic efficiency.
4Productivity
If the aerofoil is made in two parts, then the manufacturing process is simplified and efficiency is improved, but additional joining steps are required
Solution Approach 1:
The aerofoil is segmented into two body portions that can be cast independently using simplified processes. The first body portion includes the internal passage and trailing edge slot, while the second body portion closes the leading edge. These portions are then bonded together, simplifying the overall manufacturing process while maintaining structural integrity.
Data Source
AI summary
A method of manufacturing the aerofoil, and an aerofoil. The method includes: casting a first body portion having a passage passing there-through; casting a second body portion; and joining the first body portion and the second body portion to form the aerofoil. The passage extends from an opening at a first end at or near a leading edge to an opening at a second end at or near a trailing edge. The passage is formed during the casting process by a core; and the core is supported at the first and second ends through the respective openings of the passage.