U.S. patent application number 15/377796 was filed with the patent office on 2018-06-14 for multi-piece integrated core-shell structure for making cast component.
The applicant listed for this patent is GENERAL ELECTRIC COMPANY. Invention is credited to James Herbert DEINES, Michael John MCCARREN, Brian Patrick PETERSON, Brian David PRZESLAWSKI, Xi YANG.
Application Number | 20180161866 15/377796 |
Document ID | / |
Family ID | 60191527 |
Filed Date | 2018-06-14 |
United States Patent
Application |
20180161866 |
Kind Code |
A1 |
DEINES; James Herbert ; et
al. |
June 14, 2018 |
MULTI-PIECE INTEGRATED CORE-SHELL STRUCTURE FOR MAKING CAST
COMPONENT
Abstract
The present disclosure generally relates to partial integrated
core-shell investment casting molds that can be assembled into
complete molds. Each section of the partial mold may contain both a
portion of a core and portion of a shell. Each section can then be
assembled into a mold for casting of a metal part. The partial
integrated core-shell investment casting molds and the complete
molds may be provided with filament structures corresponding to
cooling hole patterns on the surface of the turbine blade or the
stator vane, which provides a leaching pathway for the core portion
after metal casting. The invention also relates to core filaments
that can be used to supplement the leaching pathway, for example in
a core tip portion of the mold.
Inventors: |
DEINES; James Herbert;
(Mason, OH) ; PRZESLAWSKI; Brian David; (Liberty
Township, OH) ; MCCARREN; Michael John; (Cincinnati,
OH) ; YANG; Xi; (Mason, OH) ; PETERSON; Brian
Patrick; (Madeira, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GENERAL ELECTRIC COMPANY |
Schenectady |
NY |
US |
|
|
Family ID: |
60191527 |
Appl. No.: |
15/377796 |
Filed: |
December 13, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22C 9/10 20130101; Y02P
10/292 20151101; B22C 9/12 20130101; B22C 13/12 20130101; B22C
13/08 20130101; B22D 25/02 20130101; F05D 2230/21 20130101; B22C
9/103 20130101; B22D 29/001 20130101; Y02P 10/25 20151101; B22D
29/00 20130101; B28B 1/001 20130101; B22C 1/22 20130101; B22C 9/02
20130101; B22C 21/14 20130101; F01D 5/12 20130101; G03F 7/00
20130101; B29C 64/124 20170801; B29C 64/129 20170801; F01D 9/041
20130101; B22C 9/108 20130101; B22D 29/002 20130101; B29C 64/135
20170801; G03F 7/20 20130101; B22C 9/24 20130101 |
International
Class: |
B22D 25/02 20060101
B22D025/02; B22C 1/22 20060101 B22C001/22; B22C 9/10 20060101
B22C009/10; B22C 9/12 20060101 B22C009/12; B22C 9/02 20060101
B22C009/02; B22C 9/24 20060101 B22C009/24; B22D 29/00 20060101
B22D029/00; F01D 9/04 20060101 F01D009/04; F01D 5/12 20060101
F01D005/12 |
Claims
1. A partial ceramic casting mold comprising: a first core portion
and a first shell portion, the first core portion and first shell
portion adapted to interface with at least a second core portion
and second shell portion to form a ceramic mold comprising a cavity
between the first and second core portions and the first and second
shell portions, the cavity adapted to define a cast component upon
casting and removal of the ceramic mold.
2. The partial ceramic casting mold of claim 1, wherein the cast
component is a turbine blade or a stator vane.
3. The partial ceramic casting mold of claim 1, wherein the first
core portion or the first shell portion includes at least one
interlocking feature adapted to interface with an interlocking
feature on the second core portion or second shell portion.
4. The partial ceramic casting mold of claim 3, wherein the
interlocking feature is an interlocking tongue or groove adapted to
fasten with a second partial ceramic casting mold.
5. The partial ceramic casting mold of claim 3, wherein the
interlocking feature is an interlocking dovetail adapted to fasten
with a second partial ceramic casting mold.
6. The partial ceramic casting mold of claim 3, wherein the
interlocking feature is a rabbet joint with an interlocking peg
adapted to fasten with a second partial ceramic casting mold.
7. The partial ceramic casting mold of claim 1, wherein the first
shell portion comprises a pin support or bumper facing the first
core portion.
8. The partial ceramic casting mold of claim 1, wherein the first
core portion comprises a pin support or bumper facing the first
core portion.
9. The partial ceramic casting mold of claim 1, wherein the ceramic
mold comprises a plurality of tie structures joining the core
portion and shell portion, the tie structures adapted to define a
plurality of holes in the cast component upon removal of the
mold.
10. The partial ceramic casting mold of claim 1, wherein the cast
component is a turbine blade or a stator vane.
11. A method for fabricating a partial ceramic mold, comprising:
(a) contacting a cured portion of a workpiece with a liquid ceramic
photopolymer; (b) irradiating a portion of the liquid ceramic
photopolymer adjacent to the cured portion through a window
contacting the liquid ceramic photopolymer; (c) removing the
workpiece from the uncured liquid ceramic photopolymer; and (d)
repeating steps (a)-(c) until a first shell portion of a partial
ceramic mold is formed and optionally a first core portion, the
optional first core portion and first shell portion adapted to
interface with at least an optional second core portion and second
shell portion to form a two piece ceramic mold comprising a cavity
between the first and/or second core portions and the first and
second shell portions, the cavity adapted to define a cast
component upon casting and removal of the ceramic mold.
12. The method of claim 11, wherein the process comprises, after
step (d), a step (e) comprising pouring a liquid metal into the two
piece ceramic mold and solidifying the liquid metal to form the
cast component.
13. The method of claim 12, wherein the process comprises, after
step (e), a step (f) comprising removing the two piece ceramic mold
from the cast component.
14. The method of claim 13, wherein removing the two piece ceramic
mold from the cast component comprises a combination of mechanical
force and chemical leaching.
15. The method of claim 11, wherein the first core portion or the
first shell portion includes at least one interlocking feature
adapted to interface with an interlocking feature on the second
core portion or second shell portion.
16. The method of claim 11, wherein the two piece ceramic mold
comprises a plurality of tie structures joining the core portion
and shell portion, the tie structures adapted to define a plurality
of holes in the cast component upon removal of the two piece
ceramic mold.
17. The method of claim 11, wherein the cast component is a turbine
blade or a stator vane.
18. The method of claim 11, wherein the first shell portion
comprises a pin support or bumper facing the first core
portion.
19. The method of claim 11, wherein the first core portion
comprises a pin support or bumper facing the first core
portion.
20. The method of claim 11, wherein the first partial ceramic mold
has a first core portion and the second partial ceramic mold has a
second core portion.
21. A method of preparing a cast component using the two piece
ceramic mold of claim 11 comprising: pouring a liquid metal into
the two piece ceramic casting mold and solidifying the liquid metal
to form the cast component; and removing the two piece ceramic mold
from the cast component.
22. A method of preparing a cast component comprising: assembling a
first core portion and a first shell portion of a two piece ceramic
mold with at least a second core portion and second shell portion
to form a two piece ceramic mold comprising a cavity between the
first and second core portions and the first and second shell
portions, the cavity adapted to define the shape of the cast
component upon casting and removal of the two piece ceramic mold;
pouring a liquid metal into the two piece ceramic casting mold and
solidifying the liquid metal to form the cast component; and
removing the two piece ceramic casting mold from the cast
component.
Description
INTRODUCTION
[0001] The present disclosure generally relates to graded
investment casting two piece core-shell mold components and
processes utilizing these components. The two piece core-shell mold
is assembled from a partial mold including a first core and shell
portion. The two piece core-shell mold is assembled by attaching
the first core and shell portion to at least a second core and
shell portion of a second partial mold. The two piece core-shell
mold made in accordance with the present invention may also include
integrated ceramic filaments between the core and shell of the mold
that can be utilized to form holes, i.e., effusion cooling holes,
in the cast component made from these two-piece molds. The use of
sufficient ceramic filaments between core and shell to both locate
and provide leaching pathways for the core serpentine also enables
the elimination of ball braze chutes. Ceramic filaments between the
tip plenum core and the shell may also be provided to support a
floating tip plenum, eliminating the need for traditional tip pins,
and their subsequent closure by brazing. The integrated core-shell
molds provide useful properties in casting operations, such as in
the casting of superalloys used to make turbine blades and stator
vanes for jet aircraft engines or power generation turbine
components.
BACKGROUND
[0002] Many modern engines and next generation turbine engines
require components and parts having intricate and complex
geometries, which require new types of materials and manufacturing
techniques. Conventional techniques for manufacturing engine parts
and components involve the laborious process of investment or
lost-wax casting. One example of investment casting involves the
manufacture of a typical rotor blade used in a gas turbine engine.
A turbine blade typically includes hollow airfoils that have radial
channels extending along the span of a blade having at least one or
more inlets for receiving pressurized cooling air during operation
in the engine. The various cooling passages in a blade typically
include a serpentine channel disposed in the middle of the airfoil
between the leading and trailing edges. The airfoil typically
includes inlets extending through the blade for receiving
pressurized cooling air, which include local features such as short
turbulator ribs or pins for increasing the heat transfer between
the heated sidewalls of the airfoil and the internal cooling
air.
[0003] The manufacture of these turbine blades, typically from high
strength, superalloy metal materials, involves numerous steps shown
in FIG. 1. First, a precision ceramic core is manufactured to
conform to the intricate cooling passages desired inside the
turbine blade. A precision die or mold is also created which
defines the precise 3-D external surface of the turbine blade
including its airfoil, platform, and integral dovetail. A schematic
view of such a mold structure is shown in FIG. 2. The ceramic core
200 is assembled inside two die halves which form a space or void
therebetween that defines the resulting metal portions of the
blade. Wax is injected into the assembled dies to fill the void and
surround the ceramic core encapsulated therein. The two die halves
are split apart and removed from the molded wax. The molded wax has
the precise configuration of the desired blade and is then coated
with a ceramic material to form a surrounding ceramic shell. Then,
the wax is melted and removed from the shell 202 leaving a
corresponding void or space 201 between the ceramic shell 202 and
the internal ceramic core 200 and tip plenum 204. Molten superalloy
metal is then poured into the shell to fill the void therein and
again encapsulate the ceramic core 200 and tip plenum 204 contained
in the shell 202. The molten metal is cooled and solidifies, and
then the external shell 202 and internal core 200 and tip plenum
204 are suitably removed leaving behind the desired metallic
turbine blade in which the internal cooling passages are found. In
order to provide a pathway for removing ceramic core material via a
leaching process, a ball chute 203 and tip pins 205 are provided,
which upon leaching form a ball chute and tip holes within the
turbine blade that must subsequently be brazed shut.
[0004] The cast turbine blade may then undergo additional
post-casting modifications, such as but not limited to drilling of
suitable rows of film cooling holes through the sidewalls of the
airfoil as desired for providing outlets for the internally
channeled cooling air which then forms a protective cooling air
film or blanket over the external surface of the airfoil during
operation in the gas turbine engine. After the turbine blade is
removed from the ceramic mold, the ball chute 203 of the ceramic
core 200 forms a passageway that is later welded shut to provide
the desired pathway of air through the internal voids of the cast
turbine blade. However, these post-casting modifications are
limited and given the ever increasing complexity of turbine engines
and the recognized efficiencies of certain cooling circuits inside
turbine blades, more complicated and intricate internal geometries
are required. While investment casting is capable of manufacturing
these parts, positional precision and intricate internal geometries
become more complex to manufacture using these conventional
manufacturing processes. Accordingly, it is desired to provide an
improved casting method for three dimensional components having
intricate internal voids.
[0005] Methods for using 3-D printing to produce a ceramic
core-shell mold are described in U.S. Pat. No. 8,851,151 assigned
to Rolls-Royce Corporation. The methods for making the molds
include powder bed ceramic processes such as disclosed U.S. Pat.
No. 5,387,380 assigned to Massachusetts Institute of Technology,
and selective laser activation (SLA) such as disclosed in U.S. Pat.
No. 5,256,340 assigned to 3D Systems, Inc. The ceramic core-shell
molds according to the '151 patent are limited by the printing
resolution capabilities of these processes. As shown in FIG. 3, the
core portion 301 and shell portion 302 of the integrated core-shell
mold is held together via a series of tie structures 303 provided
at the bottom edge of the mold. Cooling passages are proposed in
the '151 patent that include staggered vertical cavities joined by
short cylinders, the length of which is nearly the same as its
diameter. A superalloy turbine blade is then formed in the
core-shell mold using known techniques disclosed in the '151
patent, and incorporated herein by reference. After a turbine blade
is cast in one of these core-shell molds, the mold is removed to
reveal a cast superalloy turbine blade.
[0006] There remains a need to prepare ceramic core-shell molds
produced using higher resolution methods that are capable of
providing fine detail cast features in the end-product of the
casting process.
SUMMARY
[0007] The present invention relates to a novel casting mold that
is formed as a two piece core-shell mold consisting of a first
ceramic mold portion comprising a first shell portion and
optionally a first core portion and a second ceramic mold portion
comprising a second shell portion and optionally a second shell
portion, the first ceramic mold portion being adapted to interface
with the second ceramic mold portion to form a two piece ceramic
mold comprising a cavity between the first and/or second core
portions and the first and second shell portions, the cavity
adapted to define a cast component upon casting and removal of the
ceramic mold. The first and/or second ceramic mold portion may be
provided with at least one attachment point to facilitate assembly
into a complete core-shell mold. Non-limiting examples of suitable
attachment points include, for example, an interlocking
arrangement, such as for example a tongue and groove or dovetail
type attachment. Another non-limiting example of a suitable
attachment point is a rabbet joint.
[0008] In one embodiment, the invention relates to a method of
making a first partial ceramic mold having a core, a shell, and a
locking feature. The method having steps of (a) contacting a cured
portion of a workpiece with a liquid ceramic photopolymer; (b)
irradiating a portion of the liquid ceramic photopolymer adjacent
to the cured portion through a window contacting the liquid ceramic
photopolymer; (c) removing the workpiece from the uncured liquid
ceramic photopolymer; and (d) repeating steps (a)-(c) until a first
partial ceramic mold is formed, the first partial ceramic mold
comprising a core portion, a shell portion with at least one cavity
between the core portion and the shell portion, the cavity adapted
to define the shape of one side of a cast component upon casting
and removal of the first partial ceramic mold, and at least one
locking feature. After step (d), the process may further include
steps for making a cast component, for example by (e) repeating
steps (a) through (d) to make a second partial ceramic mold having
a shell and a locking feature; (f) forming a two piece ceramic mold
having a core and shell by interfacing the first partial ceramic
mold with the second partial ceramic mold via their locking
features; (g) pouring a liquid metal into the two piece ceramic
casting mold and solidifying the liquid metal to form the cast
component. After step (g), the process may further include a step
(h) comprising removing the mold from the cast component, and this
step preferably involves mechanically or physically detaching the
first ceramic mold portion from the second ceramic mold portion,
and optionally also by chemical leaching in an alkaline bath. The
step of removing the mold from the cast component can also include
leaching at least a portion of the ceramic core through the holes
in the cast component provided by the filaments.
[0009] In another embodiment, the invention relates to a method of
making a two piece ceramic mold having a core and shell, the two
piece ceramic mold being formed from a first ceramic mold portion
and a second ceramic mold portion. The method having steps of (a)
contacting a cured portion of a first workpiece with a liquid
ceramic photopolymer; (b) irradiating a portion of the liquid
ceramic photopolymer adjacent to the cured portion through a window
contacting the liquid ceramic photopolymer; (c) removing the
workpiece from the uncured liquid ceramic photopolymer; and (d)
repeating steps (a)-(c) until a first ceramic mold portion is
formed, the first ceramic mold comprising at least one locking
feature, optionally a first core portion, a first shell portion,
and if the first ceramic mold portion is formed with a first core
portion, then the first shell portion has at least one cavity
between the core portion and the shell portion, the cavity adapted
to define the shape of a first side of a cast component upon
casting and removal of the ceramic mold; (e) repeating steps
(a)-(d) with a second workpiece until a second ceramic mold portion
is formed, the second ceramic mold portion comprising at least one
locking feature, optionally a second core portion, a second shell
portion, and if the second ceramic mold portion is formed with a
second core portion, then the second shell portion has at least one
cavity between the core portion and the shell portion, the cavity
adapted to define the shape of a second side of a cast component
upon casting and removal of the two piece ceramic mold; (f)
attaching the first ceramic mold portion to the second ceramic mold
portion via their locking features to form a two piece ceramic mold
having a core and shell. After step (f), the process may further
include a step (g) of pouring a liquid metal into a two piece
casting mold and solidifying the liquid metal to form the cast
component. After step (g), the process may further include a step
(h) comprising removing the two piece mold from the cast component,
and this step preferably involves mechanically or physically
detaching the first ceramic mold portion from the second ceramic
mold portion, and optionally also chemical leaching in an alkaline
bath. The step of removing the mold from the cast component can
also include leaching at least a portion of the ceramic core
through the holes in the cast component provided by the
filaments.
[0010] In another aspect, the invention relates to a method of
preparing a cast component. The method includes steps of pouring a
liquid metal into a two piece ceramic casting mold and solidifying
the liquid metal to form the cast component, the two piece ceramic
casting mold comprising a first ceramic mold portion, a second
ceramic mold portion, a core portion, and at least one shell
portion with at least one cavity between the core portion and the
shell portion, the cavity adapted to define the shape of the cast
component upon casting and removal of the two piece ceramic mold,
and one or both of the ceramic casting mold portions further
comprising a plurality of filaments joining the core portion and
the shell portion where each filament spans between the core and
shell, the filaments adapted to define a plurality of holes in the
cast component upon removal of the two piece mold, and each ceramic
mold portion further comprising at least one attachment point; and
removing the two piece ceramic casting mold from the cast component
by detaching the first ceramic mold portion from the second ceramic
mold portion via their attachment points.
[0011] In another aspect, the invention relates to a method of
preparing a cast component. The method includes steps of assembling
a first core portion and a first shell portion of a two piece
ceramic mold with at least a second core portion and second shell
portion to form a two piece ceramic mold comprising a cavity
between the first and second core portions and the first and second
shell portions, the cavity adapted to define the shape of the cast
component upon casting and removal of the two piece ceramic mold,
pouring a liquid metal into a two piece ceramic casting mold and
solidifying the liquid metal to form the cast component, the two
piece ceramic casting mold comprising a first ceramic mold portion,
a second ceramic mold portion, a core portion, and at least one
shell portion with at least one cavity between the core portion and
the shell portion, the cavity adapted to define the shape of the
cast component upon casting and removal of the two piece ceramic
mold, and one or both of the ceramic casting mold portions further
comprising a plurality of filaments joining the core portion and
the shell portion where each filament spans between the core and
shell, the filaments adapted to define a plurality of holes in the
cast component upon removal of the two piece mold, and each ceramic
mold portion further comprising at least one attachment point; and
removing the two piece ceramic casting mold from the cast component
by detaching the first ceramic mold portion from the second ceramic
mold portion via their attachment points.
[0012] In one aspect, the cast component is a turbine blade or a
stator vane. Preferably the turbine blade or stator vane is used in
a gas turbine engine in, for example, an aircraft engine or power
generation. The turbine blade or stator vane is preferably a single
crystal cast turbine blade having a cooling hole pattern defined by
the ceramic filaments mentioned above. Preferably, the filaments
join the core portion and shell portion where each filament spans
between the core and shell, the filaments having a cross sectional
area ranging from 0.1 to 2 mm.sup.2.
[0013] The large number of filaments used to form a cooling hole
pattern may provide sufficient strength to support the tip core. If
the tip filaments are made to support tip plenum core, they may be
made larger, i.e., >2 mm cross section area, and a much lower
number of filaments, or a single filament, could be used. Although
two to four of these larger filaments is a desirable number. After
casting, any holes or notches remaining in the tip plenum sidewalls
as a result of the filaments may be brazed shut or incorporated
into the turbine blade or stator vane design, or the filaments may
be placed outside the finish machined shape of the component to
prevent the need for this.
[0014] In another aspect, the invention relates to a two piece
ceramic casting mold comprising a first ceramic casting mold
portion and a second ceramic casting mold portion, each ceramic
casting mold portion having a core portion and a shell portion with
at least one cavity between the core portion and the shell portion,
the cavity adapted to define the shape of one side of the cast
component upon casting and removal of the two piece ceramic mold; a
plurality of filaments joining the core portion and the shell
portion where each filament spans between the core and shell, the
filaments adapted to define a plurality of holes providing fluid
communication between a cavity within the cast component defined by
the core portion and an outer surface of the cast component upon
removal of the two piece mold. Preferably, the cast component is a
turbine blade or stator vane and the plurality of filaments joining
the core portion and shell portion define a plurality of cooling
holes in the turbine blade upon removal of the two piece mold.
Preferably, the plurality of filaments joining the core portion and
shell portion have a cross sectional area ranging from 0.01 to 2
mm.sup.2. The ceramic may be a photopolymerized ceramic or a cured
photopolymerized ceramic.
[0015] In one aspect, the first core portion and/or the first shell
portion includes at least one interlocking feature adapted to
interface with an interlocking feature on the second core portion
and/or second shell portion. Preferably the interlocking feature is
an interlocking tongue or groove, an interlocking dovetail or a
rabbet joint with an interlocking peg, adapted to fasten with a
second partial ceramic casting mold.
[0016] In one aspect, the first core portion and/or first shell
portion comprises a pin support or bumper facing the first core
portion or the first shell portion.
[0017] In one aspect, ceramic mold comprises a plurality of tie
structures joining the core portion and shell portion, the tie
structures adapted to define a plurality of holes in the cast
component upon removal of the mold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a flow diagram showing the steps for conventional
investment casting.
[0019] FIG. 2 is a schematic diagram showing an example of a
conventional scheme for a core-shell mold with ball chute prepared
by a conventional process.
[0020] FIG. 3 shows a perspective view of a prior art integrated
core-shell mold with ties connecting the core and shell
portions.
[0021] FIGS. 4, 5, 6 and 7 show schematic lateral sectional views
of a device for carrying out successive phases of the method
sequence for direct light processing (DLP)
[0022] FIG. 8 shows a schematic sectional view along the line A-A
of FIG. 7.
[0023] FIG. 9 shows a side view of two core-shell subassemblies and
the direction of attachment in accordance with an embodiment of the
invention.
[0024] FIG. 10 shows an assembled view of the two core-shell
subassemblies shown in FIG. 9.
[0025] FIG. 11 shows a two part integral core-shell mold with
attachment points that may be mechanically interlocked.
[0026] FIG. 12 shows an interlocking tongue and groove that can be
used to attach two core-shell subassemblies in accordance with an
embodiment of the invention.
[0027] FIG. 13 shows an interlocking dovetail that can be used to
attach two core-shell subassemblies in accordance with an
embodiment of the invention.
[0028] FIG. 14 shows a rabbet joint with integral interlocking peg
that can be used to attach two core-shell subassemblies in
accordance with an embodiment of the invention.
[0029] FIG. 15 shows a two-part integral core-shell mold including
filaments extending from the core to the shell for purposes of
providing cooling holes in the surface of a turbine blade in
accordance with an embodiment of the invention.
[0030] FIG. 16 shows a two-part integral core-shell mold including
filaments extending from the core to the shell for purposes of
providing cooling holes in the surface of a turbine blade in
accordance with an embodiment of the invention.
[0031] FIG. 17 is a schematic view of an integrated core shell mold
having core print filaments exiting beside a blade tip in
accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0032] The detailed description set forth below in connection with
the appended drawings is intended as a description of various
configurations and is not intended to represent the only
configurations in which the concepts described herein may be
practiced. The detailed description includes specific details for
the purpose of providing a thorough understanding of various
concepts. However, it will be apparent to those skilled in the art
that these concepts may be practiced without these specific
details. For example, the present invention provides a preferred
method for making cast metal parts, and preferably those cast metal
parts used in the manufacture of j et aircraft engines.
Specifically, the production of single crystal, nickel-based
superalloy cast parts such as turbine blades, vanes, and shroud
components can be advantageously produced in accordance with this
invention. However, other cast metal components may be prepared
using the techniques and integrated ceramic molds of the present
invention.
[0033] The present inventors recognized that prior processes known
for making integrated core-shell molds lacked the fine resolution
capability necessary to print filaments extending between the core
and shell portion of the mold of sufficiently small size and
quantity to result in effusion cooling holes in the finished
turbine blade. In the case of earlier powder bed processes, such as
disclosed in U.S. Pat. No. 5,387,380 assigned to Massachusetts
Institute of Technology, the action of the powder bed recoater arm
precludes formation of sufficiently fine filaments extending
between the core and shell to provide an effusion cooling hole
pattern in the cast part. Other known techniques such as selective
laser activation (SLA) such as disclosed in U.S. Pat. No. 5,256,340
assigned to 3D Systems, Inc. that employ a top-down irradiation
technique may be utilized in producing an integrated core-shell
mold in accordance with the present invention. However, the
available printing resolution of these systems significantly limits
the ability to make filaments of sufficiently small size to serve
as effective cooling holes in the cast final product.
[0034] The present inventors have found that the integrated
core-shell mold of the present invention can be manufactured using
direct light processing (DLP). DLP differs from the above discussed
powder bed and SLA processes in that the light curing of the
polymer occurs through a window at the bottom of a resin tank that
projects light upon a build platform that is raised as the process
is conducted. With DLP an entire layer of cured polymer is produced
simultaneously, and the need to scan a pattern using a laser is
eliminated. Further, the polymerization occurs between the
underlying window and the last cured layer of the object being
built. The underlying window provides support allowing thin
filaments of material to be produced without the need for a
separate support structure. In other words, producing a thin
filament of material bridging two portions of the build object is
difficult and was typically avoided in the prior art. For example,
the '151 patent discussed above in the background section of this
application used vertical plate structures connected with short
cylinders, the length of which was on the order of their diameter.
Staggered vertical cavities are necessitated by the fact that the
powder bed and SLA techniques disclosed in the '151 patent require
vertically supported ceramic structures and the techniques are
incapable of reliably producing filaments. In addition, the
available resolution within a powder bed is on the order of 1/8''
making the production of traditional cooling holes impracticable.
For example, round cooling holes generally have a diameter of less
than 2 mm corresponding to a cooling hole area below 3.2 mm.sup.2.
Production of a hole of such dimensions requires a resolution far
below the size of the actual hole given the need to produce the
hole from several voxels. This resolution is simply not available
in a powder bed process. Similarly, stereolithography is limited in
its ability to produce such filaments due to lack of support and
resolution problems associated with laser scattering. But the fact
that DLP exposes the entire length of the filament and supports it
between the window and the build plate enables producing
sufficiently thin filaments spanning the entire length between the
core and shell to form a ceramic object having the desired cooling
hole pattern. Although powder bed and SLA may be used to produce
filaments, their ability to produce sufficiently fine filaments as
discussed above is limited.
[0035] One suitable DLP process is disclosed in U.S. Pat. No.
9,079,357 assigned to Ivoclar Vivadent AG and Technische
Universitat Wien, as well as WO 2010/045950 A1 and US 2011310370,
each of which are hereby incorporated by reference and discussed
below with reference to FIGS. 4-8. The apparatus includes a tank
404 having at least one translucent bottom portion 406 covering at
least a portion of the exposure unit 410. The exposure unit 410
comprises a light source and modulator with which the intensity can
be adjusted position-selectively under the control of a control
unit, in order to produce an exposure field on the tank bottom 406
with the geometry desired for the layer currently to be formed. As
an alternative, a laser may be used in the exposure unit, the light
beam of which successively scans the exposure field with the
desired intensity pattern by means of a mobile mirror, which is
controlled by a control unit.
[0036] Opposite the exposure unit 410, a production platform 412 is
provided above the tank 404; it is supported by a lifting mechanism
(not shown) so that it is held in a height-adjustable way over the
tank bottom 406 in the region above the exposure unit 410. The
production platform 412 may likewise be transparent or translucent
in order that light can be shone in by a further exposure unit
above the production platform in such a way that, at least when
forming the first layer on the lower side of the production
platform 412, it can also be exposed from above so that the layer
cured first on the production platform adheres thereto with even
greater reliability.
[0037] The tank 404 contains a filling of highly viscous
photopolymerizable material 420. The material level of the filling
is much higher than the thickness of the layers which are intended
to be defined for position-selective exposure. In order to define a
layer of photopolymerizable material, the following procedure is
adopted. The production platform 412 is lowered by the lifting
mechanism in a controlled way so that (before the first exposure
step) its lower side is immersed in the filling of
photopolymerizable material 420 and approaches the tank bottom 406
to such an extent that precisely the desired layer thickness A (see
FIG. 5) remains between the lower side of the production platform
412 and the tank bottom 406. During this immersion process,
photopolymerizable material is displaced from the gap between the
lower side of the production platform 412 and the tank bottom 406.
After the layer thickness A has been set, the desired
position-selective layer exposure is carried out for this layer, in
order to cure it in the desired shape. Particularly when forming
the first layer, exposure from above may also take place through
the transparent or translucent production platform 412, so that
reliable and complete curing takes place particularly in the
contact region between the lower side of the production platform
412 and the photopolymerizable material, and therefore good
adhesion of the first layer to the production platform 412 is
ensured. After the layer has been formed, the production platform
is raised again by means of the lifting mechanism.
[0038] These steps are subsequently repeated several times, the
distance from the lower side of the layer 422 formed last to the
tank bottom 406 respectively being set to the desired layer
thickness A and the next layer thereupon being cured
position-selectively in the desired way.
[0039] After the production platform 412 has been raised following
an exposure step, there is a material deficit in the exposed region
as indicated in FIG. 6. This is because after curing the layer set
with the thickness A, the material of this layer is cured and
raised with the production platform and the part of the shaped body
already formed thereon. The photopolymerizable material therefore
missing between the lower side of the already formed shaped body
part and the tank bottom 406 must be filled from the filling of
photopolymerizable material 420 from the region surrounding the
exposed region. Owing to the high viscosity of the material,
however, it does not flow by itself back into the exposed region
between the lower side of the shaped body part and the tank bottom,
so that material depressions or "holes" can remain here.
[0040] In order to replenish the exposure region with
photopolymerizable material, an elongate mixing element 432 is
moved through the filling of photopolymerizable material 420 in the
tank. In the exemplary embodiment represented in FIGS. 4 to 8, the
mixing element 432 comprises an elongate wire which is tensioned
between two support arms 430 mounted movably on the side walls of
the tank 404. The support arms 430 may be mounted movably in guide
slots 434 in the side walls of the tank 404, so that the wire 432
tensioned between the support arms 430 can be moved relative to the
tank 404, parallel to the tank bottom 406, by moving the support
arms 430 in the guide slots 434. The elongate mixing element 432
has dimensions, and its movement is guided relative to the tank
bottom, such that the upper edge of the elongate mixing element 432
remains below the material level of the filling of
photopolymerizable material 420 in the tank outside the exposed
region. As can be seen in the sectional view of FIG. 8, the mixing
element 432 is below the material level in the tank over the entire
length of the wire, and only the support arms 430 protrude beyond
the material level in the tank. The effect of arranging the
elongate mixing element below the material level in the tank 404 is
not that the elongate mixing element 432 substantially moves
material in front of it during its movement relative to the tank
through the exposed region, but rather this material flows over the
mixing element 432 while executing a slight upward movement. The
movement of the mixing element 432 from the position shown in FIG.
6, to, for example, a new position in the direction indicated by
the arrow A, is shown in FIG. 7. It has been found that by this
type of action on the photopolymerizable material in the tank, the
material is effectively stimulated to flow back into the
material-depleted exposed region between the production platform
412 and the exposure unit 410.
[0041] The movement of the elongate mixing element 432 relative to
the tank may firstly, with a stationary tank 404, be carried out by
a linear drive which moves the support arms 430 along the guide
slots 434 in order to achieve the desired movement of the elongate
mixing element 432 through the exposed region between the
production platform 412 and the exposure unit 410. As shown in FIG.
8, the tank bottom 406 has recesses 406' on both sides. The support
arms 430 project with their lower ends into these recesses 406'.
This makes it possible for the elongate mixing element 432 to be
held at the height of the tank bottom 406, without interfering with
the movement of the lower ends of the support arms 430 through the
tank bottom 406.
[0042] Other alternative methods of DLP may be used to prepare the
integrated two piece core-shell molds of the present invention. For
example, the tank may be positioned on a rotatable platform. When
the workpiece is withdrawn from the viscous platform between
successive build steps, the tank may be rotated relative to the
platform and light source to provide a fresh layer of viscous
polymer in which to dip the build platform for building successive
layers.
[0043] FIG. 9 shows a schematic side view of a two piece integrated
core-shell mold 900 in accordance with an aspect of the invention.
The first piece includes a partial core 901 and partial shell 902,
and the second piece includes a partial core 903 and partial shell
904. The partial core 901 and partial shell 902 may be formed as
one integral piece, or may be separate assemblies. The partial
core-shell structures are provided with attachment points 905, 906,
907, and 908 that facilitate assembly into a complete core-shell
mold 1000 as shown in FIG. 10. The two-piece molds of the present
invention have the advantage that they can be inspected prior to
assembly and casting. Previous integral one-piece molds had the
disadvantage that due to the 3-D printed nature of the mold,
inspection of the mold before casting was difficult.
[0044] As shown in FIG. 10, the core-shell mold 1000 may include
structures integrally formed with the core 1001 or shell 1002
portion. For example, a core bumper 1003 may be provided, or a
shell bumper 1004 may be provided. Upon assembly of the two-part
mold, the bumpers 1003/1004 function to provide the required
spacing between the core 1001 and shell 1002. A pin support 1005
may be provided integral to the shell, which abuts the core portion
upon assembly of the two-part core-shell. Although not shown, a pin
structure may be provided integral to the core.
[0045] FIG. 11 shows a two-part core shell mold 1100 having a first
core/shell portion 1101/1102 and a second core-shell portion
1103/1104. In this embodiment, a first point of attachment 1105 is
provided within the tip portion of the core assembly and a second
point of attachment 1106 is provided at a portion of the shell
region distal the core tip region. FIGS. 12-14 illustrate several
non-limiting examples of attachment mechanisms provided in the
ceramic core/shell assembly. FIG. 12 illustrates an interlocking
tongue and groove type attachment 1200 with a first outside portion
1201, first inside portion 1202, second outside portion 1203, and
second inside portion 1204. FIG. 13 illustrates an interlocking
dovetail type attachment 1300 with a first outside portion 1301,
first inside portion 1302, second outside portion 1303, and second
inside portion 1304. FIG. 14 illustrates a rabbet joint with
interlocking peg having a first outside portion 1401, first inside
portion 1402, second outside portion 1403, and second inside
portion 1404.
[0046] FIG. 15 shows an example of a two-part core-shell assembly
1500 having a first core portion 1501 with attachment mechanisms
1507, 1508 and a first shell portion 1502 with attachment mechanism
1511, a second core portion 1503 with attachment mechanisms 1509,
1510 and a second shell portion 1504 with attachment mechanism
1512. The first core portion 1501 and first shell portion 1502 are
linked together with filaments 1505. The second core portion 1503
and second shell portion 1503 are linked together with filaments
1506. After casting of the metal within the core-shell mold and
leaching of the filaments, the filaments define a cooling hole
pattern in the cast turbine blade. As described in co-pending
application, GE Docket #285020, these structures are preferably
formed using the DLP process described in connection with FIGS.
4-11 above. By printing the ceramic mold using the above DLP
printing process, the mold can be made in a way that allows the
point of connections between the core and shell to be provided
through filaments 1505 and/or 1506. Once the core-shell mold is
printed, it may be subject to a post-heat treatment step to cure
the printed ceramic polymer material. The cured ceramic mold may
then be used similar to the traditional casting process used in the
production of superalloy turbine blades. Notably because the
filaments 1505 and 1506 are provided in a large quantity consistent
with formation of a pattern of effusion cooling holes in the
surface of a turbine blade, the need for a ball chute structure as
shown in FIG. 2 may be eliminated.
[0047] The filaments 1505 and 1506 are preferably cylindrical or
oval shape but may be curved or non-linear. Their exact dimensions
may be varied according to a desired film cooling scheme for a
particular cast metal part. For example cooling holes may have a
cross sectional area ranging from 0.01 to 2 mm.sup.2. In a turbine
blade, the cross sectional area may range from 0.01 to 0.15
mm.sup.2, more preferably from 0.05 to 0.1 mm.sup.2, and most
preferably about 0.07 mm.sup.2. In the case of a vane, the cooling
holes may have a cross sectional area ranging from 0.05 to 0.2
mm.sup.2, more preferably 0.1 to 0.18 mm.sup.2, and most preferably
about 0.16 mm.sup.2. The spacing of the cooling holes is typically
a multiple of the diameter of the cooling holes ranging from
2.times. to 10.times. the diameter of the cooling holes, most
preferably about 4-7.times. the diameter of the cooling holes.
[0048] The length of the filament 1505 and/or 1506 is dictated by
the thickness of the cast component, e.g., turbine blade or stator
vane wall thickness, and the angle at which the cooling hole is
disposed relative to the surface of the cast component. The typical
lengths range from 0.5 to 5 mm, more preferably between 0.7 to 1
mm, and most preferably about 0.9 mm. The angle at which a cooling
hole is disposed is approximately 5 to 35.degree. relative to the
surface, more preferably between 10 to 20.degree., and most
preferably approximately 12.degree.. It should be appreciated that
the methods of casting according to the present invention allow for
formation of cooling holes having a lower angle relative to the
surface of the cast component than currently available using
conventional machining techniques.
[0049] FIG. 16 shows a side view of an integrated core-shell mold
1600 according to an embodiment of the present invention. As with
the schematic shown in FIG. 15, the first core portion 1601 is
connected to the first shell portion 1602 through several filaments
1605. Likewise, the second core portion 1603 is connected to the
second shell portion 1604 through several filaments 1606. The first
core portion 1601 and the first shell portion 1602 can be attached
to the second core portion 1602 and the second shell portion 1604
via attachment mechanisms 1608, 1609, 1610 and 1611 to form the
complete core-shell mold assembly 1600. The assembled core-shell
mold 1600 defines a cavity 1607 for investment casting a turbine
blade. FIG. 17 shows the cavity 1607 filled with a metal 1700, such
as a nickel based alloy, i.e., Inconel. Upon leaching of the
ceramic core-shell, the resulting cast object is a turbine blade or
stator vane having a cooling hole pattern in the surface of the
blade or vane. It should be appreciated that although FIGS. 16-17
provide a cross sectional view showing cooling holes at the leading
and trailing edge of the turbine blade, that additional cooling
holes may be provided where desired including on the sides of the
turbine blades or any other location desired. In particular, the
present invention may be used to form cooling holes within the
casting process in any particular design. In other words, one would
be able to produce conventional cooling holes in any pattern where
drilling was used previously to form the cooling holes. However,
the present invention will allow for cooling hole patterns
previously unattainable due to the limitations of conventional
technologies for creating cooling holes within cast components,
i.e., drilling.
[0050] After leaching, the resulting holes in the turbine blade or
stator vane from the core print filaments may be brazed shut if
desired. Otherwise the holes left by the core print filaments may
be incorporated into the design of the internal cooling passages.
Alternatively, cooling hole filaments may be provided to connect
the tip plenum core to the shell in a sufficient quantity to hold
the tip plenum core in place during the metal casting step.
[0051] After printing the core-shell mold structures in accordance
with the invention, the core-shell mold may be cured and/or fired
depending upon the requirements of the ceramic core photopolymer
material. Molten metal may be poured into the mold to form a cast
object in the shape and having the features provided by the
integrated core-shell mold. In the case of a turbine blade or a
stator vane, the molten metal is preferably a superalloy metal that
formed into a single crystal superalloy turbine blade or stator
vane using techniques known to be used with conventional investment
casting molds.
[0052] In an aspect, the present invention relates to the
core-shell mold structures of the present invention incorporated or
combined with features of other core-shell molds produced in a
similar manner. The following patent applications include
disclosure of these various aspects and their use:
[0053] U.S. patent application Ser. No. ______, titled "INTEGRATED
CASTING CORE-SHELL STRUCTURE" with attorney docket number
037216.00036/284976, and filed Dec. 13, 2016;
[0054] U.S. patent application Ser. No. ______, titled "INTEGRATED
CASTING CORE-SHELL STRUCTURE WITH FLOATING TIP PLENUM" with
attorney docket number 037216.00037/284997, and filed Dec. 13,
2016;
[0055] U.S. patent application Ser. No. ______, titled "MULTI-PIECE
INTEGRATED CORE-SHELL STRUCTURE WITH STANDOFF AND/OR BUMPER FOR
MAKING CAST COMPONENT" with attorney docket number
037216.00042/284909A, and filed Dec. 13, 2016;
[0056] U.S. patent application Ser. No. ______, titled "INTEGRATED
CASTING CORE SHELL STRUCTURE WITH PRINTED TUBES FOR MAKING CAST
COMPONENT" with attorney docket number 037216.00032/284917, and
filed Dec. 13, 2016;
[0057] U.S. patent application Ser. No. ______, titled "INTEGRATED
CASTING CORE-SHELL STRUCTURE AND FILTER FOR MAKING CAST COMPONENT"
with attorney docket number 037216.00039/285021, and filed Dec. 13,
2016;
[0058] U.S. patent application Ser. No. ______, titled "INTEGRATED
CASTING CORE SHELL STRUCTURE FOR MAKING CAST COMPONENT WITH
NON-LINEAR HOLES" with attorney docket number 037216.00041/285064,
and filed Dec. 13, 2016;
[0059] U.S. patent application Ser. No. ______, titled "INTEGRATED
CASTING CORE SHELL STRUCTURE FOR MAKING CAST COMPONENT WITH COOLING
HOLES IN INACCESSIBLE LOCATIONS" with attorney docket number
037216.00055/285064A, and filed Dec. 13, 2016;
[0060] U.S. patent application Ser. No. ______, titled "INTEGRATED
CASTING CORE SHELL STRUCTURE FOR MAKING CAST COMPONENT HAVING THIN
ROOT COMPONENTS" with attorney docket number 037216.00053/285064B,
and filed Dec. 13, 2016.
[0061] The disclosures of each of these applications are
incorporated herein in their entirety to the extent they disclose
additional aspects of core-shell molds and methods of making that
can be used in conjunction with the core-shell molds disclosed
herein.
[0062] This written description uses examples to disclose the
invention, including the preferred embodiments, and also to enable
any person skilled in the art to practice the invention, including
making and using any devices or systems and performing any
incorporated methods. The patentable scope of the invention is
defined by the claims, and may include other examples that occur to
those skilled in the art. Such other examples are intended to be
within the scope of the claims if they have structural elements
that do not differ from the literal language of the claims, or if
they include equivalent structural elements with insubstantial
differences from the literal language of the claims. Aspects from
the various embodiments described, as well as other known
equivalents for each such aspect, can be mixed and matched by one
of ordinary skill in the art to construct additional embodiments
and techniques in accordance with principles of this
application.
* * * * *