Turbine Casting Core With High Resolution Region
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional core production methods for turbine engine components are inadequate for advanced cooling schemes, particularly in designs requiring complex internal features, as they face limitations in die separation and cannot efficiently produce high-resolution features needed for advanced cooling.
Innovation Solution
A method involving the formation of a core with a normal resolution region and a high resolution region using separate core pieces, where the high resolution region is created using tomo lithographic molding, and the pieces are joined through interlocking engagement, such as dovetail configurations, allowing for the creation of complex features like channels and grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional injection molding or transfer molding is used to manufacture the core, then the manufacturing process is simple and cost-effective, but the manufacturing precision is insufficient to produce high-resolution features required for advanced cooling schemes
Solution Approach 1:
The core is divided into multiple separate core pieces, each manufactured using tomo lithographic molding to achieve high resolution. This segmentation allows each piece to be produced with fine detail while maintaining overall manufacturability through modular assembly.
Solution Approach 2:
The patent replaces conventional mechanical injection molding or transfer molding with tomo lithographic molding, which uses photolithography and selective laser melting to create high-resolution features. This substitution enables the production of complex internal cooling channels and cavities with precision unachievable by traditional mechanical methods.
2Manufacturing precision
If the number of die segmentation planes is increased to accommodate complex core designs, then the manufacturing precision improves, but the device complexity increases making die separation impossible
Solution Approach 1:
The patent eliminates the need for multiple die segmentation planes by replacing conventional molding with tomo lithographic molding. This process uses digital modeling and selective laser melting to create complex geometries in a single forming operation, avoiding the mechanical complexity of multi-plane die separation.
Solution Approach 2:
The patent transitions from two-dimensional die separation constraints to three-dimensional digital modeling and selective laser melting. This dimensional shift allows complex internal features to be created without being constrained by the physical separation planes of mechanical dies.
3Productivity
If conventional core production methods are used, then the ease of manufacture is maintained, but the productivity is insufficient for advanced cooling schemes requiring complex internal features
Solution Approach 1:
The patent replaces slow, labor-intensive conventional molding processes with automated tomo lithographic molding, which uses digital models and selective laser melting to rapidly produce high-resolution core features. This substitution significantly increases productivity while maintaining manufacturing feasibility.
Solution Approach 2:
The patent uses digital modeling and virtual prototyping in the preliminary design phase to optimize core geometries before physical manufacturing. This preliminary digital preparation enables rapid and accurate production of complex internal cooling features without requiring complex manual manufacturing processes.
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
Enables the production of cores with intricate high-resolution features that enhance cooling performance, overcoming the limitations of conventional methods by allowing for the creation of complex internal structures that conventional core formation techniques cannot achieve.
Implementation Method 1
an interlocking engagement between a first and a second core piece is formed by thermally deforming a protrusion of the second core piece within a back happened recess of the first core piece
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A hollow turbine engine component with complex internal features can include a first region (120) and a second, high resolution region (124). The first region (120) can be defined by a first ceramic core piece formed by any conventional process, such as by injection molding or transfer molding. The second region (124) 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 (12) and the second core piece (14) can be joined by interlocking engagement that once subjected to an intermediate thermal heat treatment process thermally deform to form a three dimensional interlocking joint (132) between the first and second core pieces (12, 14) by allowing thermal creep to irreversibly interlock the first and second core pieces (12, 14) together such that the joint (132) becomes physically locked together providing joint stability through thermal processing.