EP2316593A2 - Outillage de noyau fugitif et procédé - Google Patents

Outillage de noyau fugitif et procédé Download PDF

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Publication number
EP2316593A2
EP2316593A2 EP10188114A EP10188114A EP2316593A2 EP 2316593 A2 EP2316593 A2 EP 2316593A2 EP 10188114 A EP10188114 A EP 10188114A EP 10188114 A EP10188114 A EP 10188114A EP 2316593 A2 EP2316593 A2 EP 2316593A2
Authority
EP
European Patent Office
Prior art keywords
tooling
liners
core
fugitive
ceramic
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.)
Withdrawn
Application number
EP10188114A
Other languages
German (de)
English (en)
Other versions
EP2316593A3 (fr
Inventor
Robert E. Grunstra
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.)
Howmet Corp
Original Assignee
Howmet Corp
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
Application filed by Howmet Corp filed Critical Howmet Corp
Publication of EP2316593A2 publication Critical patent/EP2316593A2/fr
Publication of EP2316593A3 publication Critical patent/EP2316593A3/fr
Withdrawn legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
    • B22C7/02—Lost patterns
    • 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 present invention relates to manufacture of a ceramic core for use in casting a hollow metallic article, such as a hollow turbine components, and more particularly, to tooling and a method for making a ceramic core.
  • a fired ceramic core is positioned in a ceramic investment shell mold to form internal cooling passageways in the cast airfoil.
  • the fired ceramic core used in investment casting of hollow airfoils typically has an airfoil-shaped region with a thin cross-section leading edge region and trailing edge region. Between the leading and trailing edge regions, the core may include elongated and other shaped openings so as to form multiple internal walls, pedestals, turbulators, ribs, chambers, plenums, and similar features separating and/or residing in cooling passageways in the cast airfoil or cast shroud.
  • the ceramic core typically is formed to desired core configuration by injection molding, transfer molding or pouring of an appropriate fluid ceramic core material that includes one or more ceramic powders, a binder, and optional additives into a suitably shaped core molding die. After the green molded core is removed from the die, it is subjected to firing at elevated (superambient) temperature in one or more steps to remove the fugitive binder and sinter and strengthen the core for use in casting metallic material, such as a nickel or cobalt base superalloy typically used to cast gas turbine engine blades and vanes (airfoils).
  • metallic material such as a nickel or cobalt base superalloy typically used to cast gas turbine engine blades and vanes (airfoils).
  • the fired ceramic core then is used in manufacture of the shell mold by the well known lost wax process wherein the ceramic core is placed in a pattern molding die and a fugitive pattern is formed about the core by injecting under pressure pattern material, such as wax, thermoplastic and the like, into the die in the space between the core the inner die walls.
  • pattern material such as wax, thermoplastic and the like
  • the pattern typically has an airfoil-shaped region with a thin cross-section trailing edge region corresponding in location to trailing edge features of the core.
  • the pattern also can include other features such as including, but not limited to, one or more platforms, shrouds and the like.
  • the fugitive pattern with the ceramic core therein is subjected to repeated steps to build up the shell mold thereon.
  • the pattern/core assembly is repeatedly dipped in ceramic slurry, drained of excess slurry, stuccoed with coarse ceramic stucco or sand, and then air dried to build up multiple ceramic layers that form the shell mold on the assembly.
  • the resulting invested pattern/core assembly then is subjected to a pattern removal operation, such as steam autoclaving, to selectively remove the fugitive pattern, leaving the shell mold with the ceramic core located therein.
  • the shell mold then is fired at elevated temperature to develop adequate shell mold strength for metal casting.
  • Molten metallic material such as a nickel or cobalt base superalloy
  • a preheated shell mold is cast into a preheated shell mold and solidified to produce an equiaxed grain, columnar grain or single crystal airfoil.
  • the resulting cast airfoil includes the ceramic core therein so as to form internal cooling passageways upon removal of the core.
  • the core can be removed by leaching or other conventional techniques, leaving a hollow cast metallic airfoil.
  • the present invention provides tooling for making a ceramic core wherein the core tooling employs one or more fugitive tooling liners and optional fugitive tooling inserts that are placed in a simple-geometry back-up or support body in a manner to form at least a portion of a core-shaped cavity and that eliminate the need for costly hardened/machined permanent steel tooling.
  • each fugitive tooling liner includes an outer surface having a simple geometry to conform to that of an adjacent inner support surface of the back-up body and an inner surface that is configured to form desired core surface features when the tooling liners are placed in the back-up body with the tooling liners forming the core-shaped cavity.
  • Optional fugitive inserts can be placed between the tooling liners to form ribs, holes, passages and other features on and/or in the ceramic core.
  • the core-shaped cavity may have one or more airfoil-shaped surfaces in the production of a ceramic core for use in casting of a hollow airfoil, such as a hollow gas turbine blade or vane, or other hollow article.
  • a ceramic core is produced pursuant to a method embodiment of the invention by introducing a fluid ceramic core mixture typically under pressure into the core-shaped cavity formed at least in part by the fugitive tooling liners in the back-up body, removing the molded ceramic core from the cavity, and removing the fugitive tooling liners with the core or from the back-up die body (separately from the core) for discarding.
  • the next ceramic core is produced using fresh (un-used) tooling liners and optional tooling inserts.
  • the fugitive tooling liners may be left in the back-up body and reused if the liners are in acceptable condition to this end. That is, the fugitive tooling liners and inserts are used in one or more production cycles (e.g. ceramic slurry injection cycles) to make a single ceramic core and then replaced with fresh (un-used) tooling liners and optional inserts.
  • the present invention provides tooling for making a ceramic core wherein the tooling employs one or more fugitive tooling liners and optional fugitive tooling inserts that are placed in a simple-geometry back-up or support body in a manner to form at least a portion of a core-shaped cavity and that eliminate the need for costly hardened/machined permanent steel tooling.
  • the invention is described in detail below with respect to making a ceramic core having an airfoil shape for use in casting metallic airfoils, such as gas turbine engine blades and vanes, it is not so limited and can be used to make a ceramic core having any desired shape.
  • an illustrative embodiment of the invention provides tooling including a back-up or support body 10 and multiple fugitive tooling liners 20a, 20b disposed in the back-up body 10 to form at least a portion of a core-shaped cavity C.
  • the back-up body 10 comprises multiple parts (first and second parts 10a, 10b shown) positionable to form a tooling cavity TC to receive the tooling liners 20a, 20b.
  • the multiple parts of the back-up body can be incorporated and positioned as an injection die of a conventional core injection machine.
  • the parts 10a, 10b of the back-up body 10 include interior flat and curved geometry surfaces 10s so as to provide a simple geometry that is not costly to machine. Although particular simple flat and curved surfaces 10s are shown, surfaces 10s of other simple geometry can be used including, but not limited to, easily-machined surfaces which are all curved or all flat, or a combination thereof, as well as other easy-to-machine surface profiles.
  • the back-up body can be made of hardened steel or other material that can withstand the pressure of the liquid ceramic material introduced typically under pressure to form the ceramic core.
  • the core tooling includes one or more fugitive tooling liners 20.
  • the core tooling is shown including first and second fugitive tooling liners 20a 20b that are placed in the tooling cavity TC.
  • Each first and second tooling liner includes an outer surface 20s having a simple flat and/or curved or other simple geometry to conform to or match that of an adjacent inner support surface 10s of an adjacent part of the back-up body 10 and an inner surface 10c that is configured to form desired core surface features when the tooling liners 20a, 20b are placed in the back-up body 10 in facing relation to form the core-shaped cavity C.
  • tooling liners are shown including flat and curved outer surfaces 20s that mate with an adjacent flat and curved surface 10s of the back-up body, other simple surfaces 20s can be used that match or mate with those of the adjacent parts of the back-up body 10.
  • the tooling liners 20a, 20b can be designed to snap-fit into place in the parts 10a, 10b of the back-up body 10, or they can be held by releasable adhesive or releasable fasteners or clamps.
  • the inner surfaces 20c of the tooling liners form an air-foil core-shaped cavity C therebetween, Figure 1A , or at least a portion of the air-foil core-shaped cavity C, Figure 1B , when the tooling liners 20a, 20b are placed in the back-up body 10.
  • simple surfaces of the core-shaped cavity C and thus the core may be formed by surfaces BS of the back-up parts 10a, 10b, as shown in Figure 1B .
  • the inner surfaces 20c are configured to form desired core surface features when the tooling liners 20a, 20b are placed in the back-up body 10 in facing or other relation to form at least a portion of the airfoil core-shaped cavity C.
  • the fugitive tooling liners typically are injection molded to shape using a suitable polymer, although other fugitive liner materials can be used including, but not limited to, polylactone, polyvinyl, and starch-modified polymers.
  • the core tooling can include one or more optional fugitive inserts 30a-30h placed between the tooling liners 20a, 20b and/or on the inner surfaces 20c of the tooling liners 20a, 20b, Figures 2 and 5 .
  • the inserts 30a-30h extending between the tooling liners can be used to form holes, passages and other through-openings in the ceramic core.
  • the inserts 30a-30h disposed on the surface 20c of the tooling liners can be used to form core surface features such as ribs, channels, shrouds, chambers, back-locked features (e.g. a dovetail joint) not easily formed in a complicated end product core.
  • the fugitive inserts alternately can be provided as fugitive subassemblies where different inserts are provided in one subassembly to form through-passages and core surface features as shown for inserts 30a and 30b in Figure 2 .
  • the fugitive inserts can be injection molded on the liner surface 20c as shown for insert 30h in Figure 2 , or as part of the liner surface as shown for insert 30g in Figure 2 .
  • the inserts 30a, 30b can be assembled from separately injection molded insert elements and located on the liner surface 20c.
  • the fugitive inserts can comprise or be incorporated as a part of the final molded core to produce a composite core having certain fugitive features such as spacers, layers, through-extending fastener, and the like for use in subsequent investment mold forming processing.
  • the fugitive inserts can include connection features to the liner surface 20c that may be normal (perpendicular) to the liner surface 20c as shown for insert 30d in Figure 2 .
  • the fugitive inserts can also include connection features to the liner surface 20c that may be normal (perpendicular) to the parting plane PP of the cavity C as shown for inserts 30e, 30f in Figure 2 .
  • a ceramic core is produced pursuant to a method embodiment of the invention by introducing a fluid ceramic core material, such as a ceramic slurry, typically under pressure into the core-shaped cavity C formed by the fugitive tooling liners 20a, 20b in the back-up body 10.
  • the fluid ceramic material is introduced via a passage CP ( Figure 1B ) in the back-up body 10.
  • the molded green (unfired) core is removed by opening the parts 10a, 10b of the back-up body 10 and removing the molded green ceramic core.
  • the fugitive tooling liners 20a, 20b are removed from the back-up die body with the molded green ceramic core, Figure 3 , or separately from the molded green core and then discarded (not re-used).
  • the optional fugitive inserts 30a-30h can be removed from the molded green ceramic core by thermal treatment to melt and/or vaporize them, solvent treatment to dissolve them, or other process that selectively removes the inserts from the molded core.
  • a final core 100 remains as shown in Figure 4 with core interior and exterior features 100a-100h formed by the respective inserts 30a-30h that have been selectively removed.
  • the next ceramic core is produced using fresh (un-used) tooling liners 20a, 20b and optional fresh tooling inserts 30. That is, the fugitive tooling liners and inserts can be used in one production cycle (e.g. ceramic injection cycle) to make a single ceramic core and then replaced with fresh (un-used) tooling liners and optional inserts. Alternately, the fugitive tooling liners may be left in the back-up body 10 and reused if the tooling liners are in acceptable condition to this end. That is, the fugitive tooling liners and inserts can be used in multiple production cycles (e.g.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
EP10188114A 2009-10-28 2010-10-19 Outillage de noyau fugitif et procédé Withdrawn EP2316593A3 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US12/589,801 US20110094698A1 (en) 2009-10-28 2009-10-28 Fugitive core tooling and method

Publications (2)

Publication Number Publication Date
EP2316593A2 true EP2316593A2 (fr) 2011-05-04
EP2316593A3 EP2316593A3 (fr) 2012-01-18

Family

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EP10188114A Withdrawn EP2316593A3 (fr) 2009-10-28 2010-10-19 Outillage de noyau fugitif et procédé

Country Status (4)

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US (1) US20110094698A1 (fr)
EP (1) EP2316593A3 (fr)
JP (1) JP2011092996A (fr)
CA (1) CA2713669A1 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012152525A1 (fr) * 2011-05-09 2012-11-15 Siemens Aktiengesellschaft Garniture pour corps de moule
CN104226906A (zh) * 2014-09-26 2014-12-24 纪汉伟 一种型腔模具的制造方法
CN105683506A (zh) * 2013-10-31 2016-06-15 西门子公司 使用利用短效镶件形成的陶瓷型芯铸造的多壁燃气涡轮翼型件和制造该翼型件的方法
WO2017160303A1 (fr) * 2016-03-18 2017-09-21 Siemens Aktiengesellschaft Procédé de fabrication d'éléments caractéristiques perfectionnés dans un noyau pour la coulée
CN112338139A (zh) * 2020-10-16 2021-02-09 中国航发北京航空材料研究院 一种控制空心涡轮工作叶片榫齿壁厚的冷蜡块及应用其实现的铸造方法

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US8814557B2 (en) * 2010-03-24 2014-08-26 United Technologies Corporation Die inserts for die casting
EP2441537A1 (fr) * 2010-10-18 2012-04-18 Siemens Aktiengesellschaft Outil à noyau doté de crayons variables et procédé de fabrication d'un noyau
US9138804B2 (en) * 2012-01-11 2015-09-22 United Technologies Corporation Core for a casting process
US9115590B2 (en) 2012-09-26 2015-08-25 United Technologies Corporation Gas turbine engine airfoil cooling circuit
US9228439B2 (en) 2012-09-28 2016-01-05 Solar Turbines Incorporated Cooled turbine blade with leading edge flow redirection and diffusion
US9206695B2 (en) 2012-09-28 2015-12-08 Solar Turbines Incorporated Cooled turbine blade with trailing edge flow metering
US9314838B2 (en) 2012-09-28 2016-04-19 Solar Turbines Incorporated Method of manufacturing a cooled turbine blade with dense cooling fin array
US9145203B2 (en) 2012-10-31 2015-09-29 The Boeing Company Natural laminar flow wingtip
US9382801B2 (en) 2014-02-26 2016-07-05 General Electric Company Method for removing a rotor bucket from a turbomachine rotor wheel
CN107427905A (zh) * 2014-10-15 2017-12-01 西门子公司 用于形成能够在燃气涡轮发动机中使用的部件的压铸系统
US20210276077A1 (en) * 2018-07-18 2021-09-09 Poly6 Technologies, Inc. Articles and methods of manufacture
US11852036B1 (en) 2023-04-19 2023-12-26 Rtx Corporation Airfoil skin passageway cooling enhancement

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012152525A1 (fr) * 2011-05-09 2012-11-15 Siemens Aktiengesellschaft Garniture pour corps de moule
CN105683506A (zh) * 2013-10-31 2016-06-15 西门子公司 使用利用短效镶件形成的陶瓷型芯铸造的多壁燃气涡轮翼型件和制造该翼型件的方法
CN104226906A (zh) * 2014-09-26 2014-12-24 纪汉伟 一种型腔模具的制造方法
WO2017160303A1 (fr) * 2016-03-18 2017-09-21 Siemens Aktiengesellschaft Procédé de fabrication d'éléments caractéristiques perfectionnés dans un noyau pour la coulée
CN108778560A (zh) * 2016-03-18 2018-11-09 西门子股份公司 制造用于铸造的型芯中的改进特征部的方法
US10807153B2 (en) 2016-03-18 2020-10-20 Siemens Aktiengesellschaft Method of manufacturing advanced features in a core for casting
CN112338139A (zh) * 2020-10-16 2021-02-09 中国航发北京航空材料研究院 一种控制空心涡轮工作叶片榫齿壁厚的冷蜡块及应用其实现的铸造方法

Also Published As

Publication number Publication date
EP2316593A3 (fr) 2012-01-18
JP2011092996A (ja) 2011-05-12
US20110094698A1 (en) 2011-04-28
CA2713669A1 (fr) 2011-04-28

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