U.S. patent application number 13/192716 was filed with the patent office on 2013-01-31 for rapid casting article manufacturing.
The applicant listed for this patent is Mario P. Bochiechio, Steven J. Bullied, Lea Kennard Castle, Kevin W. Chittenden, Agnes Klucha, John Joseph Marcin, Hector M. Pinero, Michael C. Reiter, Carl R. Verner. Invention is credited to Mario P. Bochiechio, Steven J. Bullied, Lea Kennard Castle, Kevin W. Chittenden, Agnes Klucha, John Joseph Marcin, Hector M. Pinero, Michael C. Reiter, Carl R. Verner.
Application Number | 20130026338 13/192716 |
Document ID | / |
Family ID | 46682664 |
Filed Date | 2013-01-31 |
United States Patent
Application |
20130026338 |
Kind Code |
A1 |
Castle; Lea Kennard ; et
al. |
January 31, 2013 |
RAPID CASTING ARTICLE MANUFACTURING
Abstract
A method of manufacturing a casting article for use in a casting
process includes rapidly forming the casting article out of a
metallic material. A ceramic coating is applied to an exterior
surface of the casting article.
Inventors: |
Castle; Lea Kennard;
(Vernon, CT) ; Bochiechio; Mario P.; (Vernon,
CT) ; Verner; Carl R.; (Windsor, CT) ;
Bullied; Steven J.; (Pomfret Center, CT) ; Marcin;
John Joseph; (Marlborough, CT) ; Chittenden; Kevin
W.; (Oxford, AL) ; Pinero; Hector M.;
(Middletown, CT) ; Klucha; Agnes; (Colchester,
CT) ; Reiter; Michael C.; (South Windsor,
CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Castle; Lea Kennard
Bochiechio; Mario P.
Verner; Carl R.
Bullied; Steven J.
Marcin; John Joseph
Chittenden; Kevin W.
Pinero; Hector M.
Klucha; Agnes
Reiter; Michael C. |
Vernon
Vernon
Windsor
Pomfret Center
Marlborough
Oxford
Middletown
Colchester
South Windsor |
CT
CT
CT
CT
CT
AL
CT
CT
CT |
US
US
US
US
US
US
US
US
US |
|
|
Family ID: |
46682664 |
Appl. No.: |
13/192716 |
Filed: |
July 28, 2011 |
Current U.S.
Class: |
249/114.1 ;
164/23 |
Current CPC
Class: |
B33Y 80/00 20141201;
Y02P 10/295 20151101; B22C 9/04 20130101; B22F 3/115 20130101; Y02P
10/25 20151101; B22F 3/1055 20130101; B22C 9/10 20130101; Y02P
10/292 20151101; B33Y 10/00 20141201 |
Class at
Publication: |
249/114.1 ;
164/23 |
International
Class: |
B22C 9/00 20060101
B22C009/00; B22C 9/10 20060101 B22C009/10 |
Claims
1. A method of manufacturing a casting article for use in a casting
process, comprising: (a) rapidly forming the casting article out of
a metallic material; and (b) applying a ceramic coating to an
exterior surface of the casting article.
2. The method as recited in claim 1, wherein the casting article is
a core.
3. The method as recited in claim 1, wherein the casting article is
a shell.
4. The method as recited in claim 1, comprising the step of; (c)
creating a 3D model of the casting article prior to the step of
rapidly forming the casting article.
5. The method as recited in claim 4, wherein said step (a)
comprises: forming the casting article using the 3D model.
6. The method as recited in claim 1, wherein said step (a)
comprises: forming the casting article additively layer by
layer.
7. The method as recited in claim 1, wherein said step (a)
comprises: forming the casting article using a metal deposition
process.
8. The method as recited in claim 1, wherein said step (b)
comprises: applying the ceramic coating using a deposition
process.
9. The method as recited in claim 1, wherein said step (b)
comprises: applying the ceramic coating using a spray process.
10. The method as recited in claim 1, comprising the step of: (c)
using the casting article in a casting process to cast a part.
11. A method of manufacturing a casting article for use in a
casting process, comprising: (a) forming a first metallic layer;
(b) adding a second metallic layer onto the first metallic layer;
(c) adding additional metallic layers onto the second metallic
layer to render a net-shaped casting article; and (d) applying a
coating to an exterior surface of the net-shaped casting
article.
12. The method as recited in claim 11, comprising the step of: (e)
using the net-shaped casting article in a casting process to cast a
part.
13. The method as recited in claim 11, wherein the first metallic
layer, the second metallic layer and the additional metallic layers
are formed layer by layer using a metal deposition process.
14. The method as recited in claim 11, wherein said step (d)
comprises: applying the ceramic coating using a deposition
process.
15. The method as recited in claim 11, wherein said step (d)
comprises: applying the ceramic coating using a spray process.
16. The method as recited in claim 11, Wherein said step (a)
includes: forming a melt pool on top of a substrate; and injecting
a metallic powder into the melt pool to form the first metallic
layer of the casting article.
17.-19. (canceled)
20. The method as recited in claim 7, wherein the metal deposition
process includes using a metal deposition system having a substrate
and a melting device.
21. The method as recited in claim 20, wherein the melting device
melts an ingot of the metallic material to create a melt pool on
top of the substrate and then a metallic powder is injected into
the melt pool to form a first layer of the casting article.
22. The method as recited in claim 21, wherein a 3D model that
provides the numerical data for manufacturing the casting article
is communicated to the metal deposition system prior to melting the
ingot of the metallic material and injecting the metallic
powder.
23. The method as recited in claim 1, wherein the metallic material
includes at least one of a refractory metal and a superalloy.
Description
BACKGROUND
[0001] This disclosure generally relates to a method of
manufacturing a casting article for use in a casting process.
[0002] Gas turbine engines are widely used in aircraft propulsion,
electric power generation, ship propulsion and pumps. Many gas
turbine engine parts are manufactured in a casting process.
Investment casting is one known casting process. Investment casting
can be used to form metallic parts having complex geometries, such
as gas turbine engine airfoils requiring internal cooling passages.
Blades and vanes are examples of such components.
[0003] Investment casting utilizes a plurality of casting articles,
such as shells and cores, to manufacture a part. In general, in a
time intensive process, a casting system for use in the investment
casting process is prepared having one or more cavities that define
a shape generally corresponding to the part to be cast. A wax
pattern of the component is formed by molding wax over a core. In a
shelling process, a shell is formed around one or more of the wax
patterns. The wax is melted and removed. The shell is hardened in a
firing process such that the casting system is formed comprising a
shell having one or more part defining compartments that include
the core. Typical lead times for manufacturing the casting system
tooling required for conducting the investment casting process can
range from 12 to 26 weeks or longer.
SUMMARY
[0004] A method of manufacturing a casting article for use in a
casting process includes rapidly forming the casting article out of
metallic material. A ceramic coating is applied to an exterior
surface of the casting article.
[0005] In another exemplary embodiment, a method of manufacturing a
casting article for use in a casting process includes forming a
first metallic layer of the casting article, adding a second
metallic layer on the first layer, and adding additional metallic
layers on the second metallic layer to render a net-shaped casting
article. A coating is applied to an exterior surface of the
net-shaped casting article.
[0006] In yet another exemplary embodiment, a casting system
includes a casting article having a metallic body. The casting
article is representative of a portion of the tooling of the
casting system. A ceramic coating is applied to an exterior surface
of the metallic body.
[0007] The various features and advantages of this disclosure will
become apparent to those skilled in the art from the following
detailed description. The drawings that accompany the detailed
description can be briefly described as follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates a schematic view of a gas turbine
engine.
[0009] FIG. 2 illustrates a part that can be manufactured in a
casting process.
[0010] FIG. 3 illustrates a casting system.
[0011] FIG. 4 schematically illustrates a method for manufacturing
a casting article for use in a casting system.
[0012] FIG. 5 illustrates a casting article that can be
manufactured according to the method of FIG. 4.
DETAILED DESCRIPTION
[0013] FIG. 1 illustrates an example gas turbine engine 10 that is
circumferentially disposed about an engine centerline axis A. The
gas turbine engine 10 includes (in serial flow communication) a fan
section 12, a compressor section 14, a combustor section 16 and a
turbine section 18. During operation, air is compressed in the
compressor section 14 and is mixed with fuel and burned in the
combustor section 16. The combustion gases are discharged through
the turbine section 18, which extracts energy from the combustion
gases for powering the compressor section 14 and the fan section
12, among other potential loads.
[0014] The gas turbine engine 10 includes a plurality of parts that
can be manufactured in a casting process, such as an investment
casting process or other suitable casting process. For example,
both the compressor section 14 and the turbine section 18 include
numerous airfoils, such as alternating rows of rotating blades 20
and stationary vanes 22, that can be manufactured in a casting
process.
[0015] This view is highly schematic and is included to provide a
basic understanding of the gas turbine engine 10 and not to limit
the disclosure. This disclosure extends to all types of gas turbine
engines and for all types of applications.
[0016] FIG. 2 illustrates a part 24 that may be manufactured using
a casting process, such as an investment casting process. In this
example, the part 24 is a vane 22 of the turbine section 18.
However, the various features and advantages of this disclosure are
applicable to any cast part of a gas turbine engine, or any other
part.
[0017] FIG. 3 illustrates an example casting system 26 that can be
used in a casting process to cast a part, including but not limited
to, a part similar to the part 24 of FIG. 2. The casting system 26
includes a core 28 and a shell 30. The core 28 is positioned and
spaced relative to the shell 30 in a known manner. The core 28
creates any internal features of the part, such as cooling
passages, for example. The shell 30 forms the external shape and
features of the part.
[0018] In a casting process, a casting alloy is introduced into the
casting system 26 to cast a part, such as by pouring, for example.
Upon cooling and solidifying of the casting alloy, the part is
removed from the casting system 26 as is known. Of course, this
view is highly schematic and is included to provide a basic
understanding of a casting system. The shape, placement and
configuration of the core 28 and the shell 30 and any other tooling
of the casting system 26 will vary depending upon the type of part
being cast.
[0019] FIG. 4, with continued reference to FIGS. 1-3, schematically
depicts an example method 100 for manufacturing a casting article
32 for use in a casting process. In this disclosure, the term
"casting article" is intended to describe any tooling associated
with a casting system. For example, the example method 100 can be
used to manufacture the core 28, the shell 30 or any other
associated tooling of a casting system.
[0020] The method 100 begins at step block 102 where a 3D model 50
of the casting article 32 is created. The 3D model 50 can be made
using known computer hardware and software. The 3D model 50
includes numerical data that defines the shape (including any
internal surfaces) and any dimensional aspects of the casting
article 32. The 3D model 50 is used to manufacture the casting
article 32.
[0021] The casting article 32 is next rapidly formed out of a
metallic material at step block 104. In this disclosure, the term
"rapid" is intended to describe a process that can be performed in
hours or days rather than weeks or months. In other words, a
net-shaped casting article 32 can be manufactured from a metallic
material in a relatively short period of time according to the
various features and advantages of this disclosure.
[0022] In one example, the casting article 32 is manufactured using
a metal deposition process that additively forms the casting
article 32 layer by layer. A metal deposition system 200 can be
used to rapidly cast the casting article 32. The 3D model 50 is
communicated to the metal deposition system 200 and provides the
necessary numerical data for manufacturing the casting article 32.
A person of ordinary skill in the art would understand how to
communicate the 3D model 50 to the metal deposition system 200.
[0023] The example metal deposition system 200 includes a substrate
34 and a melting device 36, such as one or more lasers. The melting
device 36 melts an ingot of metallic material 38 to create a melt
pool 40 on top of the substrate 34. A metallic powder 42 is
injected into the melt pool 40 to form a first layer L1 of the
casting article 32. A second layer L2 is formed onto the first
layer L1 of the casting article 32. Additional metallic layers L3
through Ln can also be formed onto the second layer L2 to rapidly
render a net-shaped casting article 32 in a layer by layer process.
The total number of metallic layers Ln for any given casting
article will vary depending upon the size, shape and configuration
of the casting article. The metal deposition system 200 is shown
schematically in order to illustrate the potential features of such
a system and not to limit this disclosure in any way.
[0024] The term "metal deposition process" as used in this
disclosure is intended to describe any additive metal fabrication
technology. Example metal deposition processes include direct metal
deposition, direct metal laser sintering, laser consolidation,
selective laser melting, high energy electron beam direct metal
processing, fuse deposition modeling, ion fusion formation, and
fuse deposition melting. These processes are included as examples
only, and the metal deposition process used in conjunction with the
method 100 could include a combination of such processes or any
other additive metal fabrication process.
[0025] The casting article 32 is manufactured from a metallic
material. In one example, the metallic material includes a
refractory metal. In another example, the metallic material
includes a superalloy. Other metallic materials may also be
suitable for manufacturing the casting article 32.
[0026] At step block 106, a ceramic coating is applied to an
exterior surface of the casting article 32 previously formed at
step block 104. Example ceramic coatings include, but are not
limited to, Yttria Stabilized Zirconia (YSZ), Zirconia-based
coatings, Alumina-based coatings, Silica-based coatings,
Alumino-Silicate based coatings, Mullite-based coatings and
Oxide-based coatings.
[0027] The ceramic coating can be applied using a deposition
process, a spray process or other known coating processes,
including but not limited to, air plasma spray (APS), magnetron
sputtering, slurry coating, high velocity oxygen fuel (HVOF), low
pressure plasma spray (LPPS), cathodic arc, chemical vapor
deposition (CVD), electron beam plasma vapor deposition (EB-PVD),
plasma deposition and/or impact illuminization. The ceramic coating
protects the casting article 32 from alloying into the casting
alloy during a casting process.
[0028] Finally, at step block 108, the rapidly formed casting
article 32 is utilized in a casting process to cast a part. For
example, the casting article 32 can be used in the casting system
26 depicted by FIG. 3 to investment cast a gas turbine engine part
24, such as a turbine airfoil. The casting article 32 is evacuated
during the casting process to render the part 24.
[0029] FIG. 5 illustrates an example casting article 32
manufactured according to the exemplary method 100 described above.
In this example, the casting article 32 is a core for use in a
casting process. The casting article 32 can be used to form the
internal cooling passages of a gas turbine engine part 24. The
casting article 32 includes a metallic body 44 that defines an
outer surface 46. A ceramic coating 48 is applied to the outer
surface 46 of the metallic body 44 to protect the metallic body 44
from alloying into the casting alloy during the casting process.
The ceramic coating 48 can be applied to the entire outer surface
46 or only a portion of the outer surface 46. It should be
understood that this disclosure extends to additional tooling of a
casting system, including but not limited to the shell of the
casting system.
[0030] The foregoing description shall be interpreted as
illustrative and not in any limiting sense. A worker of ordinary
skill in the art would understand that certain modifications could
come within the scope of this disclosure. For these reasons, the
following claims should be studied to determine the true scope and
content of this disclosure.
* * * * *