Studded Spacer Core Assembly for Casting Wall Thickness Control
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Solution Overview
Problem
Maintaining wall thicknesses during the casting process of complex gas turbine engine components with internal cooling passageways is difficult due to the thin-walled constructions and the need to control spacing between the core assembly and the surrounding shell.
Innovation Solution
A core assembly with spacers that include a stud portion and a chaplet portion, which abut the core and shell to maintain spacing, and may include features like bumpers, recesses, and threadable or riveted attachments to secure the spacers, ensuring proper wall thickness during casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If thin-walled constructions are used to create complex internal cooling passageways, then the complexity of internal geometry is improved, but the difficulty of maintaining wall thickness specifications deteriorates
Solution Approach 1:
A spacer acts as an intermediary component between the core assembly and the shell, maintaining a controlled gap to ensure consistent wall thickness. The spacer includes a stud portion that attaches to the core and a chaplet portion that contacts the shell, effectively mediating the spacing relationship to prevent direct contact and maintain dimensional precision throughout the casting process.
2Manufacturing precision
If spacers are added to control spacing between core and shell, then manufacturing precision is improved, but device complexity deteriorates
Solution Approach 1:
The spacer is segmented into distinct functional portions: a stud portion for attachment to the core assembly and a chaplet portion for contact with the shell. This segmentation allows each portion to be optimized for its specific function while maintaining overall simplicity. The segmented design enables modular assembly and simplifies the attachment mechanism compared to attempting to create a single complex spacing component.
Data Source
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AI summary
The disclosure provides a core assembly (84; 184) for a casting system, comprising: a core (86; 186; 586) that includes a body and at least one hole (94; 194; 594) formed through said body; and a spacer (92; 192; 292; 392; 492; 592-1) that extends through said at least one hole (94; 194; 594), said spacer (92; 192; 292; 392; 492; 592-1) including a stud portion (96; 196; 296; 396; 496; 596) and a chaplet portion configured (98; 198; 298; 398; 498; 598) to abut a surface (91; 191) of said body that circumscribes said at least one hole (94; 194; 294). A casting system is also provided.