Gas Turbine Wing Element Manufacturing via Directional Solidification

The patent extracts and eliminates the core component from the manufacturing process. Instead of using a separate core that needs to be prepared and inserted into the mold, the invention uses a mold cavity that directly forms the internal structure of the wing element. This removes the core preparation step entirely while maintaining the ability to produce complex internal geometries with high physical properties.

The patent inverts the traditional casting approach by forming the wing element directly in the mold cavity without requiring a removable core. The mold cavity itself defines the final internal geometry, eliminating the need for core extraction or removal. This inversion simplifies the manufacturing process while maintaining precision casting benefits.

The patent changes the key parameter of manufacturing method from additive three-dimensional printing to direct cast formation in a mold. This parameter change enables the production of wing elements with microstructural properties equivalent to precision casting while retaining simplified process benefits. The mold-based approach allows for controlled solidification and grain structure formation that improves physical properties.

The patent employs composite manufacturing approach by combining mold-based casting with selective material deposition or reinforcement techniques. The final product integrates materials with optimized microstructures that achieve both high physical properties and manufacturing efficiency, bridging the gap between precision casting quality and additive manufacturing simplicity.

The patent applies preliminary action by pre-forming the mold cavity with the exact internal geometry required for the wing element before the casting process begins. This eliminates the need for subsequent core removal or post-processing operations. The mold is prepared in advance with precise dimensions and surface finishes that directly transfer to the final product, maintaining manufacturing precision while reducing overall cycle time.

The patent extracts the time-consuming core preparation and removal steps from the manufacturing process. By using a permanent mold cavity that directly forms the internal structure, the process eliminates the need to prepare, insert, and later remove cores. This extraction of unnecessary steps significantly reduces manufacturing time while maintaining precision through the rigid mold geometry.