EP1358958B1 - A way to manufacture inserts for steam cooled hot gas path components - Google Patents

A way to manufacture inserts for steam cooled hot gas path components Download PDF

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Publication number
EP1358958B1
EP1358958B1 EP03252630A EP03252630A EP1358958B1 EP 1358958 B1 EP1358958 B1 EP 1358958B1 EP 03252630 A EP03252630 A EP 03252630A EP 03252630 A EP03252630 A EP 03252630A EP 1358958 B1 EP1358958 B1 EP 1358958B1
Authority
EP
European Patent Office
Prior art keywords
casting
insert
inserts
hot gas
gas path
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Revoked
Application number
EP03252630A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP1358958A1 (en
Inventor
Robert H. Devine
James M. Placko
Justin W. Downs
Jon C. Schaeffer
Lance G. Peterson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=29215557&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=EP1358958(B1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by General Electric Co filed Critical General Electric Co
Publication of EP1358958A1 publication Critical patent/EP1358958A1/en
Application granted granted Critical
Publication of EP1358958B1 publication Critical patent/EP1358958B1/en
Anticipated expiration legal-status Critical
Revoked legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
    • B22D29/001—Removing cores
    • B22D29/002—Removing cores by leaching, washing or dissolving
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/02—Sand moulds or like moulds for shaped castings
    • B22C9/04—Use of lost patterns

Definitions

  • the invention relates to a way to manufacture inserts for steam cooled hot gas path components.
  • Inserts are required in air and steam cooled nozzles to provide impingement cooling to airfoil walls and ribs.
  • the prior art methods of production of inserts use sheet metal forming operations, including welding and brazing, and electro discharge machining of the holes. Such a method is for instance disclosed in EP 0 974 735.
  • the problem with the prior art methods is that the large complicated inserts combined with strict dimensional tolerances result in 3D structures that have a very low yield relative to design specifications. This problem is solved by the metod defined in claim 1. Preferred embodiments are defined in dependent claims.
  • the process casts the inserts to tight tolerance using any ceramic core casting process such as, for example, pressure casting, centrifugal casting, squeeze casting or vacuum casting (also known as counter gravity casting).
  • Counter gravity casting as employed by Hitchiner Manufacturing Co., Inc. of Milford, New Hampshire uses metal dies with a vacuum pour to help fill thin sections of the casting and eliminate porosity.
  • the core material is then used as a backer during subsequent drilling operations.
  • the core is removed by acid leaching and the cast parts are machined, if necessary, to finish specifications.
  • the method facilitates the production of complicated 3D insert geometrics in a Ni-base superalloy with thin walls and tight tolerances.
  • the method also provides for accurate and precise drilling of the cast inserts with improved processing times and fixtures.
  • the method also solves the problems in the prior art by using the ceramic core in the insert casting process to act as a backer for laser drilling.
  • the laser holes then facilitate the use of leachant to quickly remove the core, speeding the manufacturing process.
  • the method uses, for example, Hitchiner's thin wall casting process to produce the insert geometry from a wax model.
  • the Hitchiner process substitutes counter gravity casting for more conventional casting by, for example, gravity pouring.
  • wax replicas of the desired castings are produced by injection molding. Depending on the size of the castings, multiple wax replicas may be attached to a central waxed stick, termed a sprue, to thereby form a casting assembly. Thereafter, a ceramic shell is formed around the casting or the casting assembly made up of the multiple wax replicas of the desired castings. Next, the ceramic is dried and the wax is melted out creating a negative impression of the casting assembly within the ceramic shell.
  • FIG. 1 schematically shows a cast insert 10 with ceramic core 12 shown in place by dotted lines. Also shown is laser drilling apparatus 14 prior to the drilling process.
  • the cast inserts are made from IN625 (Ni-base superalloy).
  • the ceramic core is not immediately leached out. Instead the casting is put in a fixture for laser drilling holes with the ceramic core still in place.
  • the casting tolerances are such that a fixture can handle a production run without a lot of rework.
  • FIG. 1 schematically shows insert 10 after holes 16 have been drilled by laser drilling apparatus 14.
  • FIG. 3 schematically shows ceramic 12 being removed by immersing cast insert 10 in acid bath 18.
  • Another advantage of the inventive method is the reduction in the number of heat treatments that the part goes through relative to current state of the art processing. Reducing heat treatments reduces the amount of distortion caused by residual stresses and results in higher quality.
  • the invention will produce inserts and baffles for hot gas path hardware at a greater level of performance and yield.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Laser Beam Processing (AREA)
EP03252630A 2002-04-25 2003-04-25 A way to manufacture inserts for steam cooled hot gas path components Revoked EP1358958B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/131,137 US20030201087A1 (en) 2002-04-25 2002-04-25 Way to manufacture inserts for steam cooled hot gas path components
US131137 2002-04-25

Publications (2)

Publication Number Publication Date
EP1358958A1 EP1358958A1 (en) 2003-11-05
EP1358958B1 true EP1358958B1 (en) 2005-03-30

Family

ID=29215557

Family Applications (1)

Application Number Title Priority Date Filing Date
EP03252630A Revoked EP1358958B1 (en) 2002-04-25 2003-04-25 A way to manufacture inserts for steam cooled hot gas path components

Country Status (5)

Country Link
US (1) US20030201087A1 (es)
EP (1) EP1358958B1 (es)
JP (1) JP2004003470A (es)
KR (1) KR20030084716A (es)
DE (1) DE60300436T2 (es)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9579714B1 (en) 2015-12-17 2017-02-28 General Electric Company Method and assembly for forming components having internal passages using a lattice structure

Families Citing this family (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8828214B2 (en) * 2010-12-30 2014-09-09 Rolls-Royce Corporation System, method, and apparatus for leaching cast components
JP6057778B2 (ja) 2013-02-27 2017-01-11 本田技研工業株式会社 レーザ加工装置
EP2971532A4 (en) * 2013-03-15 2016-11-16 United Technologies Corp ADDITIVE FOR THE MANUFACTURE OF DEFLECTORS, COVERS AND MATRICES
US10150158B2 (en) 2015-12-17 2018-12-11 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10099276B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having an internal passage defined therein
US9968991B2 (en) 2015-12-17 2018-05-15 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US10046389B2 (en) 2015-12-17 2018-08-14 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10099284B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having a catalyzed internal passage defined therein
US10118217B2 (en) 2015-12-17 2018-11-06 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US9987677B2 (en) 2015-12-17 2018-06-05 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10137499B2 (en) 2015-12-17 2018-11-27 General Electric Company Method and assembly for forming components having an internal passage defined therein
US10099283B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having an internal passage defined therein
US10286450B2 (en) 2016-04-27 2019-05-14 General Electric Company Method and assembly for forming components using a jacketed core
US10335853B2 (en) 2016-04-27 2019-07-02 General Electric Company Method and assembly for forming components using a jacketed core
US10315248B2 (en) 2016-11-17 2019-06-11 General Electric Company Methods and apparatuses using cast in core reference features
CN106825503A (zh) * 2017-03-15 2017-06-13 江苏钜源机械有限公司 机车发动机水冷缸体的负压消失模铸造方法

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3694264A (en) * 1970-09-28 1972-09-26 Stuart L Weinland Core removal
US3858290A (en) * 1972-11-21 1975-01-07 Avco Corp Method of making inserts for cooled turbine blades
GB2105624A (en) * 1981-09-02 1983-03-30 Rolls Royce Turbine blade manufacture
US5465780A (en) * 1993-11-23 1995-11-14 Alliedsignal Inc. Laser machining of ceramic cores
US6237344B1 (en) * 1998-07-20 2001-05-29 General Electric Company Dimpled impingement baffle

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9579714B1 (en) 2015-12-17 2017-02-28 General Electric Company Method and assembly for forming components having internal passages using a lattice structure

Also Published As

Publication number Publication date
US20030201087A1 (en) 2003-10-30
DE60300436D1 (de) 2005-05-04
DE60300436T2 (de) 2006-02-09
EP1358958A1 (en) 2003-11-05
JP2004003470A (ja) 2004-01-08
KR20030084716A (ko) 2003-11-01

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