Segmented Ceramic Casting Core for Turbine Cooling Channels
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Solution Overview
Problem
Conventional core production methods for turbine engine components are limited in their ability to incorporate advanced internal cooling features, particularly due to the difficulty in designing cores with multiple separation planes, which restricts the complexity and resolution of cooling channels and passages.
Innovation Solution
A casting core system with distinct high-resolution and normal-resolution regions, where high-resolution features are achieved using tomo lithographic molding, allowing for complex and intricate designs that exceed conventional die separation limitations, and the core pieces are joined using interlocking features like dovetails and undercuts for enhanced precision and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional injection molding or transfer molding is used to manufacture cores, then the manufacturing process is relatively simple, but the core design is limited by the number of die separation planes required, making it impossible to achieve advanced cooling features
Solution Approach 1:
The core is divided into multiple segments that can be separately manufactured using conventional molding techniques, then assembled together using joining features. This segmentation allows each segment to be produced with simpler dies while achieving complex overall core geometries that would otherwise require impossible numbers of separation planes.
Solution Approach 2:
Joining features such as protrusions and recesses act as intermediaries between core segments. These features enable the assembly of multiple segments into a functional core with advanced cooling channels and passages, bridging the gap between simple manufacturing processes and complex design requirements.
2Manufacturing precision
If the number of die separation planes is increased to accommodate more complex core features, then the core can include more advanced cooling features, but it becomes increasingly challenging and eventually impossible to separate the dies
Solution Approach 1:
By segmenting the core into multiple pieces, each manufactured in separate dies with reasonable separation planes, the overall complex geometry is achieved through assembly rather than requiring an impossible number of die separation planes in a single molding process.
Solution Approach 2:
The solution moves from a single-die limitation to a multi-piece assembly approach, adding the dimension of assembly operations. This allows cooling channels and passages to be formed with high precision across multiple segments while avoiding the die separation impossibility that would result from attempting to mold the entire complex geometry in one piece.
3Adaptability or versatility
If conventional core production methods are used, then manufacturing costs are controlled, but advanced internal cooling features cannot be incorporated
Solution Approach 1:
The core is segmented into multiple manufacturable pieces that can be produced using conventional, cost-effective molding techniques. These segments are then joined to create advanced cooling features, maintaining cost control while achieving previously unattainable cooling channel and passage designs.
Solution Approach 2:
Multiple core segments with individual cooling features are merged through joining features to create a unified core with sophisticated internal cooling channels and passages. This combining approach enables advanced cooling capabilities while using conventional manufacturing processes for each individual segment.
Data Source
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AI summary
A turbine engine component, such as a turbine blade or vane, with complex internal features can be cast using a core having a first region with normal resolution features and a second region with high resolution features. The core can be formed from a single structure. Alternatively, the first region can be defined by a first ceramic core piece, which can be formed by any conventional process, such as by injection molding or transfer molding. The second region can be defined by a second ceramic core piece formed separately by a method effective to produce high resolution features, such as tomo lithographic molding. The first core piece and the second core piece can be joined by interlocking engagement, such as by male and female dovetails. The high resolution features can be effective to produce high efficiency internal cooling features in the cast component