U.S. patent application number 11/219156 was filed with the patent office on 2007-03-01 for investment casting pattern manufacture.
This patent application is currently assigned to United Technologies Corporation. Invention is credited to Keith A. Santeler.
Application Number | 20070044933 11/219156 |
Document ID | / |
Family ID | 37622476 |
Filed Date | 2007-03-01 |
United States Patent
Application |
20070044933 |
Kind Code |
A1 |
Santeler; Keith A. |
March 1, 2007 |
INVESTMENT CASTING PATTERN MANUFACTURE
Abstract
At least one feed core and at least one wall cooling core are
assembled with a number of elements of a die for forming a cooled
turbine engine element investment casting pattern. A sacrificial
material is molded in the die. The sacrificial material is removed
from the die. The removing includes extracting a first of the die
elements from a compartment in a second of the die elements before
disengaging the second die element from the sacrificial material.
The first element includes a compartment receiving an outlet end
portion of a first of the wall cooling cores in the assembly and
disengages therefrom in the extraction.
Inventors: |
Santeler; Keith A.;
(Middletown, CT) |
Correspondence
Address: |
BACHMAN & LAPOINTE, P.C. (P&W)
900 CHAPEL STREET
SUITE 1201
NEW HAVEN
CT
06510-2802
US
|
Assignee: |
United Technologies
Corporation
|
Family ID: |
37622476 |
Appl. No.: |
11/219156 |
Filed: |
September 1, 2005 |
Current U.S.
Class: |
164/44 ; 164/45;
164/516 |
Current CPC
Class: |
B22C 9/064 20130101;
B22C 7/02 20130101; B22C 9/103 20130101; B22C 21/14 20130101; B22C
9/04 20130101 |
Class at
Publication: |
164/044 ;
164/045; 164/516 |
International
Class: |
B22C 9/04 20060101
B22C009/04 |
Goverment Interests
U.S. GOVERNMENT RIGHTS
[0001] The invention was made with U.S. Government support under
contract F33615-97-C-2779 awarded by the US Air Force. The U.S.
Government has certain rights in the invention.
Claims
1. A method for manufacturing a cooled turbine engine element
investment casting pattern comprising: assembling at least one feed
core and at least one wall cooling core with a plurality of
elements of a die; molding a sacrificial material in the die; and
removing the sacrificial material from the die, wherein the
removing comprises: extracting a first of the die elements from a
compartment in a second of the die elements before disengaging the
second element from the sacrificial material, the first element
including a compartment receiving an outlet end portion of a first
of the wall cooling cores in the assembling and disengaging
therefrom in the extracting, the extracting of the first die
element releasing a backlocking between the first wall cooling core
and the second element.
2. The method of claim 1 used to manufacture an airfoil element
wherein the wall cooling core is an airfoil cooling core.
3. The method of claim 1 wherein: the outlet end portion comprises
a first plurality of tabs from a first row of tabs; and a third of
the die elements includes a compartment receiving a second
plurality of tabs from the first row of tabs in an assembling and
disengaging therefrom in an extracting.
4. The method of claim 1 wherein: the disengaging the second
element from the sacrificial material comprises a first extraction
in a first direction; and the extracting the first die element is
in a second direction off-parallel to the first direction.
5. The method of claim 4 wherein: the second direction is
off-parallel to the first direction by 5-60.degree..
6. The method of claim 1 wherein: the outlet end portion comprises
a plurality of outlet-forming tabs; and the first element comprises
a plurality of compartments for receiving associated ones of the
tabs.
7. The method of claim 6 wherein: the plurality of outlet-forming
tabs are arranged in first and second rows; and the first element
receives at least some of the tabs of both said first and second
rows.
8. The method of claim 1 wherein the removing comprises: extracting
a third of the die elements from a compartment in a fourth of the
die elements before disengaging the fourth element from the
sacrificial material, the third element including a compartment
receiving an outlet end portion of the a second of the wall cooling
cores in the assembling and disengaging therefrom in the extracting
of the third die element.
9. The method of claim 8 wherein: the disengaging the fourth
element from the sacrificial material comprises extraction opposite
the first direction; and the extracting the third die element is in
a third direction off-parallel to the first direction.
10. The method of claim 1 wherein: the sacrificial material
comprises a wax; the at least one feed core comprises a first
ceramic feed core; the first wall cooling core comprises a
refractory metal-based substrate.
11. The method of claim 1 wherein: the first wall cooling core is
positioned to form a counterflow heat exchanger.
12. The method of claim 11 wherein: the outlet end portion is
oriented to form outlet slots inclined 15-60.degree. off normal to
an adjacent surface.
13. The method of claim 1 wherein: the first wall cooling core is
positioned to form a parallel flow heat exchanger.
14. An apparatus for manufacturing an investment casting pattern
for a cooled turbine engine element comprising: a plurality of main
die elements assemblable to an assembled configuration for
containing a feed core and forming a cavity therearound for
receiving sacrificial pattern material; and a plurality of die
inserts carried by the main die elements for receiving associated
outlet end portions of a plurality of the wall cooling cores and
extractable from the main die elements to release a backlocking of
the wall cooling cores relative to the main die elements.
15. The apparatus of claim 14 wherein: at least a first of the
inserts has at least first and second rows of compartments for
receiving first and second rows of tabs of the outlet end portion
of the associated wall cooling core.
16. A casting core comprising: a main body for forming a cooling
circuit within a wall of a turbine airfoil and having first and
second spanwise ends, an inlet end, and an outlet end and curved to
conform to an adjacent surface of the wall; and a plurality of tabs
extending from the outlet end and including at least two parallel
tabs.
17. The core of claim 16 wherein: the at least two parallel tabs
include at least two tabs from each of at least two rows of
tabs.
18. (canceled)
19. The core of claim 16 wherein: the at least two parallel tabs
include at least two tabs bent back relative to the body and
separated therefrom by less than 80.degree..
20. The method of claim 1 wherein: the extracting consists
essentially of a linear extraction.
21. The method of claim 1 wherein removing comprises: extracting a
third of the die elements from a compartment in a second of the die
elements before disengaging the second element from the sacrificial
material, the third element including a compartment receiving an
outlet end portion of a second of the wall cooling cores in the
assembling and disengaging therefrom in the extracting of the third
die element, the extracting of the third die element releasing a
backlocking between the second wall cooling core and the second
element.
Description
BACKGROUND OF THE INVENTION
[0002] The invention relates to investment casting. More
particularly, the invention relates to investment casting of cooled
turbine engine components.
[0003] Investment casting is a commonly used technique for forming
metallic components having complex geometries, especially hollow
components, and is used in the fabrication of superalloy gas
turbine engine components.
[0004] Gas turbine engines are widely used in aircraft propulsion,
electric power generation, ship propulsion, and pumps. In gas
turbine engine applications, efficiency is a prime objective.
Improved gas turbine engine efficiency can be obtained by operating
at higher temperatures, however current operating temperatures in
the turbine section exceed the melting points of the superalloy
materials used in turbine components. Consequently, it is a general
practice to provide air cooling. Cooling is typically provided by
flowing relatively cool air, e.g., from the compressor section of
the engine, through passages in the turbine components to be
cooled. Such cooling comes with an associated cost in engine
efficiency. Consequently, there is a strong desire to provide
enhanced specific cooling, maximizing the amount of cooling benefit
obtained from a given amount of cooling air. This may be obtained
by the use of fine, precisely located, cooling passageway
sections.
[0005] A well developed field exists regarding the investment
casting of internally-cooled turbine engine parts such as blades
and vanes. In an exemplary process, a mold is prepared having one
or more mold cavities, each having a shape generally corresponding
to the part to be cast. An exemplary process for preparing the mold
involves the use of one or more wax patterns of the part. The
patterns are formed by molding wax over ceramic cores generally
corresponding to positives of the cooling passages within the
parts. In a shelling process, a ceramic shell is formed around one
or more such patterns in well known fashion. The wax may be removed
such as by melting in an autoclave. The shell may be fired to
harden the shell. This leaves a mold comprising the shell having
one or more part-defining compartments which, in turn, contain the
ceramic core(s) defining the cooling passages. Molten alloy may
then be introduced to the mold to cast the part(s). Upon cooling
and solidifying of the alloy, the shell and core may be
mechanically and/or chemically removed from the molded part(s). The
part(s) can then be machined and/or treated in one or more
stages.
[0006] The ceramic cores themselves may be formed by molding a
mixture of ceramic powder and binder material by injecting the
mixture into hardened metal dies. After removal from the dies, the
green cores are thermally post-processed to remove the binder and
fired to sinter the ceramic powder together. The trend toward finer
cooling features has taxed ceramic core manufacturing techniques.
The fine features may be difficult to manufacture and/or, once
manufactured, may prove fragile. Commonly-assigned co-pending U.S.
Pat. No. 6,637,500 of Shah et al. discloses exemplary use of a
ceramic and refractory metal core combination. Other configurations
are possible. Generally, the ceramic core(s) provide the large
internal features such as trunk passageways while the refractory
metal core(s) provide finer features such as outlet passageways.
Assembling the ceramic and refractory metal cores and maintaining
their spatial relationship during wax overmolding presents numerous
difficulties. A failure to maintain such relationship can produce
potentially unsatisfactory part internal features. Depending upon
the part geometry and associated core(s), it may be difficult to
assembly fine refractory metal cores to ceramic cores. Once
assembled, it may be difficult to maintain alignment. The
refractory metal cores may become damaged during handling or during
assembly of the overmolding die. Assuring proper die assembly and
release of the injected pattern may require die complexity (e.g., a
large number of separate die parts and separate pull directions to
accommodate the various RMCs). U.S. patent application Ser. No.
10/867,230, by Carl Verner et al. filed Jun. 14, 2004 and entitled
INVESTMENT CASTING, discloses the pre-embedding of RMCs in wax
bodies shaped to help position the core assembly and facilitate die
separation and pattern removal.
SUMMARY OF THE INVENTION
[0007] One aspect of the invention involves a method for
manufacturing a cooled turbine engine element investment casting
pattern. At least one feed core and at least one airfoil wall
cooling core are assembled with a number of elements of a die. A
sacrificial material is molded in the die and is then removed from
the die. The removing includes extracting a first of the die
elements from a compartment in a second of the die elements before
disengaging the second die element from the sacrificial material.
The first element includes a compartment receiving an outlet end
portion of a first of the wall cooling cores in the assembly and
disengages therefrom in the extraction.
[0008] In various implementations, the disengaging of the second
element from the sacrificial material may include a first
extraction in a first direction. The extracting of the first die
element may be in a second direction off-parallel to the first
direction. The first extraction may release a backlocking between
the first wall cooling core and the second element. The second
direction may be off-parallel to the first direction by
5-60.degree..
[0009] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a streamwise sectional view of a turbine airfoil
element.
[0011] FIG. 2 is a tip-end view of a core assembly for forming the
element of FIG. 1.
[0012] FIG. 3 is a view of a refractory metal core of the assembly
of FIG. 2.
[0013] FIG. 4 is an end view of the refractory metal core of FIG.
3.
[0014] FIG. 5 is an inlet end view of the RMC of FIG. 4.
[0015] FIG. 6 is an inlet end view of an alternate refractory metal
core.
[0016] FIG. 7 is a streamwise sectional view of a pattern-forming
die.
[0017] Like reference numbers and designations in the various
drawings indicate like elements.
DETAILED DESCRIPTION
[0018] FIG. 1 shows an exemplary airfoil 20 of a gas turbine engine
element. An exemplary element is a blade wherein the airfoil is
unitarily cast with an inboard platform and attachment root for
securing the blade to a disk. Another example is a vane wherein the
blade is unitarily cast with an outboard shroud and, optionally, an
inboard platform. Other examples include seals, combustor panels,
and the like. The exemplary airfoil 20 has a leading edge 22 and a
trailing edge 24. A generally convex suction side 26 and a
generally concave pressure side 28 extend between the leading and
trailing edges. In operation, an incident airflow is split into
portions 500 and 502 along the suction and pressure sides
(surfaces) 26 and 28, respectively.
[0019] The exemplary airfoil 20 includes an internal cooling
passageway network. An exemplary network includes a plurality of
spanwise extending passageway legs 30A-30G from upstream to
downstream. These legs carry one or more flows of cooling air
(e.g., delivered through the root of a blade or the shroud of a
vane). Outboard of the legs, the airfoil has suction and pressure
side walls 32 and 34. To cool the walls 32 and 34, the passageway
network includes cooling circuits 40A-40E each extending from one
or more of the passageway legs 30A-30G to the suction or pressure
sides.
[0020] In the example of FIG. 1, there are two circuits along the
suction side: an upstream circuit 40A; and a downstream circuit
40B. There are three circuits along the pressure side: an upstream
circuit 40C; an intermediate circuit 40D; and a downstream circuit
40E. Although not shown, there may be a circuit extending from the
downstreammost leg 30G to or near to the trailing edge 24. There
may also be additional circuits along a leading portion of the
airfoil. Each of the circuits 40A-40E has one or more inlets 42 at
the associated passageway leg or legs. As is discussed in further
detail below, in the exemplary airfoil, the inlets 42 of each
circuit are formed as a single spanwise row of inlets. With
multiple spanwise rows, however, other configurations are possible
including the feeding of a given circuit from more than one of the
legs. Each circuit extends to associated outlets. In the exemplary
airfoil, each circuit extends to two rows of outlets 44 and 46. As
is discussed in further detail below, the exemplary outlets of each
row are streamwise staggered. Between the inlets and outlets, a
main portion 48 of each circuit may extend through the associated
wall 32 or 34 in a convoluted fashion.
[0021] In the exemplary airfoil, the circuits 40A-40D are oriented
as counterflow circuits (i.e., airflow through their main portions
48 is generally opposite the adjacent airflow 500 or 502). The
exemplary circuit 40E is positioned for parallel flow heat
exchange. In the exemplary circuits, the outlets are angled
slightly off-normal to the surface 26 or 28 in a direction with the
associated flow 500 or 502. For example, FIG. 1 shows a local
surface normal 504 and an axis 506 of the outlets separated by an
angle .theta..sub.1. This angle helps enhance flow through the
circuit by improving entrainment of the outlet flows 508 and 510
(shown exaggerated). The angle may also help provide a film cooling
effect on the surface to the extent the cool from the flows 508 and
510 air stays closer to the surface.
[0022] An investment casting process is used to form the turbine
element. In the investment casting process, a sacrificial material
(e.g., a hydrocarbon based material such as a natural or synthetic
wax) is molded over a sacrificial core assembly. The core assembly
ultimately forms the passageway network. After shelling of the
pattern (e.g., by a multi-stage stuccoing process) and removal of
the wax (e.g., by a steam autoclave) metal is cast in the shell.
Thereafter, the shell and core assembly are removed from the
casting. For example, the shell may be mechanically broken away and
the core assembly may be chemically leached from the casting.
[0023] FIG. 2 shows an exemplary investment casting core assembly
60. The assembly includes one or more ceramic cores, illustrated in
FIG. 2 as a single ceramic feed core 62, and a number of refractory
metal cores (RMCs) 64A-64E. Exemplary RMCs are formed from
molybdenum sheet stock and may have a protective coating (e.g.,
ceramic). Alternative RMC substrate materials include refractory
metal-based alloys and intermetallics. As is discussed below, the
RMCs 64A-64E respectively form the circuits 40A-40E in the cast
part. The feed core 62 includes a proximal root 66 and a series of
spanwise portions 68A-68G. The spanwise portions respectively form
the passageways 30A-30G in the cast part.
[0024] Each of the exemplary RMCs (FIG. 3) includes a main body 80.
The body 80 has first and second faces 82 and 84 and may have a
number of apertures 86 for forming pedestals, dividing walls, or
other features in the associated circuit 40A-40E. The body extends
between first and second spanwise ends 88 and 90 and from an inlet
end 92 to an outlet end 94. At the inlet end, an array of tabs 96
extend from the body 80. The tabs have proximal portions 98
bent/curved to orient the tab away from the local orientation of
the body 80. Exemplary tabs 96 have straight terminal portions 100
extending to distal ends 102. When assembled to the feed core 60,
the distal ends 102 engage the feed core (e.g., contacting a
surface of or received within a compartment of the associated
spanwise portion(s) 68A-68G).
[0025] Similarly, at the outlet end 94, first and second arrays of
tabs 110 and 112, respectively, extend from the body 80. The tabs
110 and 112 have proximal portions 114 and 116, respectively,
bent/curved to orient the tab away from the local orientation of
the body 80. The exemplary tabs 110 and 112 have straight terminal
portions 118 and 120, respectively, extending to distal ends 122
and 124. When assembled to the feed core 60, the distal ends 122
and 124 are positioned to engage a die assembly (discussed below)
for molding the pattern wax over the core assembly. In the pattern
and cast part, the tabs 96 form the circuit inlets 42 and the tabs
110 and 112 form the circuit outlets 44 and 46, respectively.
[0026] As is discussed in further detail below, the terminal
portions 100 of the tabs 96 have central axes 520. The terminal
portions 118 and 120 of the tabs 110 and 112 have respective
central axes 522 and 524. FIG. 4 shows the exemplary axes 522 as
parallel to each other in spanwise projection. Similarly, the
exemplary axes 524 are parallel to each other in spanwise
projection. In the exemplary embodiment, the axes 522 and 524 are
also parallel to each other. Similarly, the exemplary axes 520 are
parallel to each other. The axes may be fully parallel to each
other (e.g., not merely in a spanwise projection). For example,
FIG. 5 shows the tabs 96 as parallel when viewed approximately
streamwise. FIG. 3 also shows the terminal portions 100 of the tabs
96 at an angle .theta..sub.2 to the adjacent portion of the main
body 80. The terminal portions 118 and 120 of the tabs 110 and 112
are shown at an angle .theta..sub.3 to the adjacent portion of the
main body 80. The exemplary main body 80 is curved (e.g., having
appropriate streamwise convexity or concavity for the suction or
pressure side, respectively, and having appropriate twist for that
side). Accordingly, .theta..sub.2 and .theta..sub.3 may vary
spanwise. For example, they may be well under 90.degree. at one
spanwise end, transitioning to over 90.degree. at the other.
Exemplary low values for .theta..sub.3 are less than 80.degree.,
more particularly about 30-75.degree. or 40-70.degree.. Exemplary
larger values are the supplements (180.degree.-x) of these.
[0027] FIG. 6 shows an alternate group of tabs 140 connected by a
terminal bridging portion 142 (e.g., distinguished from the free
tips of other tabs). This construction may provide greater handling
robustness.
[0028] The parallelism of the outlet tabs (or of groups of the
outlet tabs) may facilitate pattern manufacture. FIG. 7 shows a
pattern-forming die assembly 200. The assembly 200 includes two or
more die main elements 202 and 204. The assembly 200 also includes
a number of die inserts 210A-210E, each carried by an associated
one of the die main elements 202 or 204. The die assembly defines
an internal surface 220 forming a compartment for containing the
core assembly 60 and molding the pattern wax 222 over the core
assembly 60.
[0029] For ease of reference, the die main elements 202 and 204 may
be respectively identified as upper and lower die elements,
although no absolute orientation is required. In general, such die
elements are installed to each other by a linear insertion in a
direction 540 and, after molding, are separated by extraction in an
opposite direction 541. With two such main elements, this
extraction is known as a single pull. However, some pattern
configurations do not permit single pull molding because the shape
of the molded wax may create a backlocking effect. In such a
situation, there may be an additional main element. FIG. 7 shows,
in broken line, such an additional element 224 and its associated
pull direction 542.
[0030] Use of the RMCs presents additional backlocking
considerations. Specifically, the tabs, if not oriented parallel to
the pull of the associated die main element, may cause backlocking.
To decouple tab orientation from the associated die main element
pull direction, the assembly 200 utilizes the inserts 210A-210E.
Each of the inserts 210A-210E is received in an associated
compartment 230A-230E in the associated die main element 202 or
204. Each insert 210A-210E includes an end surface 232 which
ultimately forms a part of the surface 220. Extending inward from
the surface 232 are rows of compartments 234 and 236. The
compartments 234 and 236 are positioned to receive the terminal
portions of the associated outlet tabs 110 and 112.
[0031] It can be seen in FIG. 7 that with the inserts 210A-210E in
place, the RMCs backlock the upper die half 202 against extraction
in the direction 541. A similar result would occur in the absence
of the inserts (i.e., if the inserts were unitarily formed with
their associated die halves). One alternative to prevent such
backlocking would be to orient the terminal portions 118 and 120
parallel to the direction of extraction 541. However, this
orientation could either reduce flexibility in selecting the outlet
orientation or impose manufacturing difficulties.
[0032] Accordingly, in an exemplary method of manufacture, the RMCs
may be preassembled to the feedcore. The RMCs may be positioned
relative to the feedcore such as by wax pads (not shown) between
the RMC main bodies and the feedcore. The RMCs may be secured to
the feedcore such as by melted wax drops or a ceramic adhesive
along the contact region between the RMC inlet end terminal
portions 100 and the feedcore. The die main elements are initially
assembled around the core assembly 60 with the inserts 210A-210E
fully or slightly retracted. The inserts 210A and 210E are, then,
inserted in respective directions 550A-550E. During the insertion,
the terminal portions 118 and 120 of each RMC are received by the
associated compartments 234 and 236 of the associated insert
210A-210E. After introduction of the wax 222, the inserts 210A-210E
may be fully or partially retracted in a direction 551A-551E,
opposite the associated direction 550A-550E. The retraction may be
simultaneous or staged. In one exemplary staged retraction, the
inserts in one of the die halves (e.g., 210A and 210B in the upper
die half 202) are first retracted while the other inserts 210C-210E
remain in place. The upper die half 202 may then be disengaged from
the lower die half 204 and pattern by extraction in the direction
541. During this extraction, the backlocking of the inserts
210C-210E to their associated RMCs helps maintain the pattern
engaged to the lower die half. Thereafter, the inserts 210C-210E
may be retracted to permit removal of the pattern from the lower
die half (e.g., by lifting the pattern in the direction 541).
[0033] One or more embodiments of the present invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention. For example, details of the particular
parts being manufactured may influence details of any particular
implementation. Also, if implemented by modifying existing
equipment, details of the existing equipment may influence details
of any particular implementation. Accordingly, other embodiments
are within the scope of the following claims.
* * * * *