EP3206814A1 - Die cast system for forming a component usable in a gas turbine engine - Google Patents

Die cast system for forming a component usable in a gas turbine engine

Info

Publication number
EP3206814A1
EP3206814A1 EP14796598.2A EP14796598A EP3206814A1 EP 3206814 A1 EP3206814 A1 EP 3206814A1 EP 14796598 A EP14796598 A EP 14796598A EP 3206814 A1 EP3206814 A1 EP 3206814A1
Authority
EP
European Patent Office
Prior art keywords
inner liner
sub
die
wall
die cast
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.)
Granted
Application number
EP14796598.2A
Other languages
German (de)
French (fr)
Other versions
EP3206814B1 (en
Inventor
Ching-Pang Lee
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.)
Siemens AG
Mikro Systems Inc
Original Assignee
Siemens AG
Mikro Systems Inc
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 Siemens AG, Mikro Systems Inc filed Critical Siemens AG
Publication of EP3206814A1 publication Critical patent/EP3206814A1/en
Application granted granted Critical
Publication of EP3206814B1 publication Critical patent/EP3206814B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • 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
    • 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
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D17/00—Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure
    • B22D17/20—Accessories: Details

Definitions

  • This invention is directed generally to die cast systems, and more particularly to manufacturing methods for turbine airfoils usable in turbine engines.
  • Turbine blade airfoils typically have internal cooling systems formed from a plurality of cooling channels, as shown in Figure 2 and 3.
  • a casting mold is often used and includes an internal ceramic core and external ceramic shell.
  • the ceramic core as shown in Figure 1 , is manufactured to include detail features on the core die surface in order to form efficient cooling devices inside the blade casting.
  • the core dies typically used to form cores are most often formed from hard steel, which are expensive to
  • the core die surfaces are typically in direct contact with the ceramic core material during the high pressure injection process.
  • the core die will wear out after sufficient injections and lead to non-conforming casting.
  • the core die needs to be reworked or replaced when a core die becomes worn, which is an expensive endeavor. Even a small improvement on an internal surface requires that a completely new die be made. Thus, a need exists for a more robust, less expensive system.
  • a die cast system having an inner liner insert that enables the configuration of a component produced by the system to be easily changed by changing the inner liner insert without having to rework the die housing is disclosed. Because the inner liner insert only need be removed and replaced to change the configuration of an outer surface of a component produced by the system, the cost savings is significant in contrast with conventional systems in which the die would have to be reworked.
  • the die cast system may also include an inner liner formed from first and second end sub-inner liners, whereby the first end sub-inner liner may be from a first material that is less compliant than a material forming the second end sub-inner liner enabling more intricate cooling systems to be created by the second end sub-inner liner that is formed from a more compliant material.
  • the die cast system may include a die housing having one or more inner chambers forming an insert receiving chamber and one or more inner liners positioned within the insert receiving chamber of the inner chamber of the die housing.
  • the inner liner may have an inner surface defining boundaries useful to form an inner surface of a turbine component, whereby the inner liner may be formed via a selective laser melting process.
  • the inner liner may be formed from a first side sub-inner liner forming a first side of the turbine component and a second side sub-inner liner forming a second side of the turbine component.
  • the first side sub-inner liner may form an outer wall of a suction side of an airfoil usable in a gas turbine engine and may include at least one cavity on an inner side of the outer wall that is configured to form at least a portion of an internal airfoil cooling system.
  • the second side sub-inner liner may form an outer wall of a pressure side of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the outer wall that is configured to form at least a portion of an internal airfoil cooling system.
  • the inner liner may be formed from a non- ceramic, flexible material.
  • the inner liner may be formed from a different material than the die housing.
  • the die housing may be formed from a first sub-die housing and a second sub-die housing having a mateable interface positioned therebetween such that the first and second sub-die housings are mateable at the mateable interface.
  • the inner liner may be formed from a first end sub- inner liner forming a first end of the turbine component and a second end sub-inner liner forming a second end of the turbine component.
  • the first end sub-inner liner may be formed from a first material that is less compliant than a material forming the second end sub-inner liner.
  • the second end sub-inner liner being more compliant may be used to form intricate aspects to the internal cooling system.
  • the first end sub-inner liner may be configured to form a leading edge of an airfoil usable in a turbine engine and second end sub-inner liner is configured to form a trailing edge of the airfoil usable in the turbine engine.
  • the first end sub-inner liner may be formed from a first end, first side sub-inner liner and a first end, second side sub-inner liner.
  • the first end, first side sub-inner liner may form a suction side outer wall of an upstream portion of a suction side of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the suction side outer wall that is configured to form at least a portion of an internal airfoil cooling system.
  • the first end, second side sub-inner liner may form a pressure side outer wall of a pressure side of the upstream portion of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the pressure side outer wall that is configured to form at least a portion of an internal airfoil cooling system.
  • the second end sub-inner liner may be formed from a second end, first side sub-inner liner and a second end, second side sub-inner liner.
  • the second end, first side sub-inner liner may form a suction side outer wall of a downstream portion of a suction side of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the suction side outer wall that is configured to form at least a portion of an internal airfoil cooling system.
  • the second end, second side sub-inner liner may form a pressure side outer wall of a pressure side of the downstream portion of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the pressure side outer wall that is configured to form at least a portion of an internal airfoil cooling system.
  • a method of forming a turbine component may include injecting a ceramic material into at least one inner cavity formed within a composite die cast system, wherein the die cast system may be formed from a die housing having one or more inner chambers forming an insert receiving chamber and one or more inner liners positioned within the insert receiving chamber of the inner chamber of the die housing.
  • the inner liner may have an inner surface defining boundaries useful to form an inner surface of a turbine component.
  • the inner liner may be formed via a selective laser melting process.
  • the method may also include removing the die cast system thereby revealing a ceramic core.
  • the method may include firing the ceramic core, placing the ceramic core within an inner cavity formed by an inner surface of a wax die, and injecting wax into one or more openings formed between the ceramic core and the inner surface of the wax die.
  • the method may also include removing the wax die to reveal a wax component, coating the wax component with a ceramic coating to form a ceramic shell with a ceramic core positioned therein and removing the wax component within the ceramic coating leaving one or more cavities within the ceramic coating.
  • the method may also include filling the cavity within the ceramic coating with a molten metal and removing the ceramic shell and the ceramic core to form a cast
  • An advantage of the composite die cast system is that because the inner liner insert only need be removed and replaced to change the configuration of an inner surface of a component produced by the system, a significant cost savings is captured in contrast with conventional systems in which the die would have to be reworked.
  • hybrid die cast system Another advantage of the hybrid die cast system is that use of the hybrid die cast system will reduce time and effort required to create a core die in a conventional casting process.
  • the inner liner may be formed from different portions formed from different materials, thereby enabling portions of the inner liner proximate to aspects of the core where intricate aspects of an internal cooling system are located, to be formed from more compliant material enabling those intricate aspects of the internal cooling system to be formed.
  • Figure 1 is a perspective view of a conventionally formed core.
  • Figure 2 is a cross-sectional view of two adjacent conventional turbine airfoils.
  • Figure 3 is a cross-sectional view of a conventional turbine airfoil with an internal cooling system.
  • Figure 4 is a cross-sectional view of an inner liner of the die cast system.
  • Figure 5 is a cross-sectional view of an inner liner positioned within a die housing of the die cast system.
  • Figure 6 is a cross-sectional view of a ceramic material injected within the inner liner positioned within a die housing of the die cast system.
  • Figure 7 is a cross-sectional view of a ceramic core.
  • Figure 8 is a cross-sectional view of a ceramic core after firing.
  • Figure 9 is a cross-sectional view of a ceramic core after firing placed in a wax die and wax injected into the openings between the ceramic core and the wax die.
  • Figure 10 is a cross-sectional view of a wax pattern with the ceramic core and with the wax die removed.
  • Figure 1 1 is a cross-sectional view of the wax pattern with a ceramic shell formed around the wax pattern.
  • Figure 12 is a cross-sectional view of the ceramic shell and ceramic core with the wax pattern removed.
  • Figure 13 is a cross-sectional view of the ceramic shell and ceramic core with molten metal in the ceramic casting mold.
  • Figure 14 is a casting of a component with the ceramic shell and ceramic core removed.
  • Figure 15 is a flow chart of a method of forming a casting component, such as, but not limited to, an airfoil from cast metal.
  • Figure 16 is a cross-sectional view of an alternative inner liner of the die cast system.
  • Figure 17 is a cross-sectional view of the alternative inner liner of Figure 16 positioned within a die housing of the die cast system.
  • Figure 18 is a cross-sectional view of a ceramic material injected within the alternative inner liner of Figure 16 positioned within a die housing of the die cast system.
  • Figure 19 is a cross-sectional view of a ceramic core.
  • Figure 20 is a cross-sectional view of a ceramic core after firing.
  • Figure 21 is a cross-sectional view of a ceramic core after firing placed in a wax die and wax injected into the openings between the ceramic core and the wax die.
  • Figure 22 is a cross-sectional view of a wax pattern with the ceramic core and with the wax die removed.
  • Figure 23 is a cross-sectional view of the wax pattern with a ceramic shell formed around the wax pattern.
  • Figure 24 is a cross-sectional view of the ceramic shell and ceramic core with the wax pattern removed.
  • Figure 25 is a cross-sectional view of the ceramic shell and ceramic core with molten metal in the ceramic casting mold.
  • Figure 26 is a casting of a component with the ceramic shell and ceramic core removed.
  • Figure 27 is a perspective view of a turbine airfoil formed with the die cast system of Figures 4-14 and 16-26 and via the method of using the system shown in Figure 15.
  • Figure 28 is a cross-sectional view of the turbine airfoil taken along section line 28-28 in Figure 27.
  • a die cast system 10 having an inner liner insert 12 that enables the configuration of a component 14 produced by the system 10 to be easily changed by changing the inner liner insert 12 without having to rework the die housing 16 is disclosed. Because the inner liner insert 12 only need be removed and replaced to change the configuration of an inner surface 18 of a component 14 produced by the system 10, the cost savings is significant in contrast with
  • the die cast system 10 may also include an inner liner 12 formed from first and second end sub- inner liners 20, 22, whereby the first end sub-inner liner 20 may be from a first material that is less compliant than a material forming the second end sub-inner liner 22 enabling more intricate cooling systems to be created by the second end sub- inner liner 22, which is more compliant than the first end inner liner 20.
  • the die cast system 10 may include a die housing 16 may have one or more inner chambers 23 forming an insert receiving chamber 24.
  • the die cast system 10 may also include one or more inner liners 12 positioned within the insert receiving chamber 24 of the inner chamber 24 of the die housing 16.
  • the inner liner 12 may have an inner surface 26 defining boundaries useful to form an inner surface 18 of a turbine component 14.
  • the inner surface 26 of the inner liner 12 may be configured to form an airfoil 138 usable in a gas turbine engine.
  • the airfoil 138 may be formed from a generally elongated, hollow airfoil 140 having a leading edge 142 on an opposite side from a trailing edge 144 and separated by a concave pressure side 146 and a convex suction side 148.
  • the generally elongated, hollow airfoil 60 may have one or more film cooling holes 150 at one or more of the leading edge 142 forming a showerhead, concave pressure side 146, the convex suction side 148 or the trailing edge 144, or any combination thereof.
  • the inner liner 12 may be formed via a selective laser melting process, with a material such as, but not limited to, iron.
  • the inner liner 12 may be formed from a first side sub-inner liner 30 forming a first side 32 of the turbine component 14 and a second side sub-inner liner 34 forming a second side 36 of the turbine component 14.
  • the first side sub-inner liner 30 may be formed from an outer wall 38 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48.
  • the second side sub-inner liner 34 may form an outer wall 50 of a pressure side 52 of the airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the outer wall 50 that is configured to form at least a portion of an internal airfoil cooling system 48.
  • the first side sub-inner liner 30 and the second side sub-inner liner 34 may together form a plurality of inner cavities 44 forming the internal airfoil cooling system 48.
  • the inner liner 12 may be formed from a non- ceramic material, such as, but not limited to, iron, or another appropriate material.
  • the inner liner 12 may be formed from a different material than the die housing 16.
  • the die housing 16 may be formed from a first sub-die housing 58 and a second sub-die housing 60 having a mateable interface 62 positioned therebetween such that the first and second sub-die housings 58, 60 are mateable at the mateable interface 62.
  • the inner liner 12 may be formed from a first end sub-inner liner 20 forming a first end 64 of the turbine component 14 and a second end sub-inner liner 22 forming a second end 66 of the turbine component 14.
  • the first end sub-inner liner 20 may be formed from a first material that is less compliant than a material forming the second end sub-inner liner 22. As such, that less compliant material may be used to form intricate aspects of the internal cooling system 48.
  • the second end sub- inner liner 22 form from the less compliant material may be formed by processes employed by Mikro Systems of Charlottesville, VA.
  • the first end sub-inner liner 20 may be configured to form a leading edge 70 of an airfoil shaped core 42 usable in a turbine engine
  • second end sub-inner liner 22 may be configured to form a trailing edge 72 of the airfoil shaped core 42 usable in the turbine engine.
  • the first end sub-inner liner 20 may be formed from a first end, first side sub-inner liner 74 and a first end, second side sub-inner liner 76.
  • the first end, first side sub-inner liner 74 may form a suction side outer wall 38 of an upstream portion 78 of a suction side 40 of an airfoil shaped core 42.
  • the first end, first side sub-inner liner 74 may include one or more cavities 44 on an inner side 46 of the suction side outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48.
  • the first end, second side sub-inner liner 76 may form a pressure side outer wall 50 of a pressure side 52 of the upstream portion 78 of an airfoil shaped core 42.
  • the first end, second side sub-inner liner 76 may include one or more cavities 44 on an inner side 56 of the pressure side outer wall 50 that is configured to form at least a portion of the internal airfoil cooling system 48.
  • the second end sub-inner liner 22 may be formed from a second end, first side sub-inner liner 80 and a second end, second side sub-inner liner 82.
  • the second end, first side sub-inner liner 80 may form a suction side outer wall 38 of a downstream portion 84 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the suction side outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48.
  • the second end, second side sub-inner liner 82 may form a pressure side outer wall 50 of a pressure side 52 of the downstream portion 84 of the airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the pressure side outer wall 50 that is configured to form at least a portion of the internal airfoil cooling system 48.
  • a method 100 of forming a turbine component 14 may include forming a ceramic core die 90 at 101 and Figures 4 and 16 via a selective laser melting process.
  • the die 90 may be positioned within a die housing 16 at 102 and Figures 5 and 17.
  • the method 100 may also include injecting a ceramic material 98 at 103 and Figures 6 and 18 into one or more inner cavities 44 formed within a die cast system 10 in which the die cast system 10 may be formed from a die housing 16 having one or more inner chambers 23 forming an insert receiving chamber 24.
  • the die cast system 10 may also include one or more inner liners 12 positioned within the insert receiving chamber 24 of the inner chamber 23 of the die housing 16.
  • the inner liner 12 may have an inner surface 26 defining boundaries useful to form an inner surface 18 of a turbine component 14.
  • the inner liner 12 may be formed via a selective laser melting process.
  • the method may include removing the die cast system 10 at 104 and Figures 7 and 19 thereby revealing a ceramic core 90.
  • the method may also include firing the ceramic core 90 at 106 and Figures 8 and 20 and placing the ceramic core 90 at 108 within an inner cavity 92 formed by an inner surface 94 of a wax die 96.
  • the method may also include injecting wax 88 at 1 10 and Figures 9 and 21 into at least opening 92 formed between the ceramic core 90 and the inner surface 94 of the wax die 96.
  • the method may include removing the wax die 96 at 1 12 and Figures 10 and 22 to reveal a wax component 86 and coating the wax component 86 at 1 14 and Figures 1 1 and 23 with a ceramic coating 1 16 to form a ceramic shell 1 18 with a ceramic core 90 positioned therein.
  • the method may include removing the wax component 86 at 120 and Figures 12 and 24 within the ceramic coating 1 16 leaving one or more cavities 122 within the ceramic coating 1 16.
  • the method may include filling the cavity 122 at 124 and Figures 13 and 25 within the ceramic coating 1 16 with a molten metal and removing the ceramic shell 1 18 and the ceramic core 90 at 126 and Figures 14 and 26 to form a cast component 14.
  • the step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the inner liner 12 is formed from a first side sub-inner liner 30 forming a first side 32 of the turbine component 14 and a second side sub-inner liner 34 forming a second side 36 of the turbine component 14.
  • the step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the first side sub-inner liner 30 may form an outer wall 38 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48.
  • the second side sub-inner liner 34 may form an outer wall 50 of a pressure side 52 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the outer wall 50 that is configured to form at least a portion of an internal airfoil cooling system 48.
  • the step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the inner liner 12 may be formed from a first end sub-inner liner 20 forming a first end 64 of the turbine component 14 and a second end sub- inner liner 22 forming a second end 66 of the turbine component 14, wherein the first end sub-inner liner 20 may be formed from a first material having a less compliant than a material forming the second end sub-inner liner 22.
  • the step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the first end sub-inner liner 20 may be formed from a first end, first side sub-inner liner 74 and a first end, second side sub-inner liner 76, and wherein the first end, first side sub-inner liner 74 may form a suction side outer wall 38 of an upstream portion 78 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the suction side outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48.
  • the first end, second side sub-inner liner 76 may form a pressure side outer wall 50 of a pressure side 52 of the upstream portion 78 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the pressure side outer wall 50 that is configured to form at least a portion of an internal airfoil cooling system 48.
  • the step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the second end sub-inner liner 22 may be formed from a second end, first side sub-inner liner 80 and a second end, second side sub-inner liner 82, and wherein the second end, first side sub-inner liner 80 may form a suction side outer wall 38 of a downstream portion 84 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the suction side outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48.
  • the second end, second side sub-inner liner 82 may form a pressure side outer wall 50 of a pressure side 52 of the downstream portion 84 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the pressure side outer wall 50 that is configured to form at least a portion of an internal airfoil cooling system 48.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

A die cast system (10) having an inner liner insert (12) that enables the configuration of a component (14) produced by the system to be easily changed by changing the inner liner insert (12) without having to rework the die housing (16) is disclosed. Because the inner liner insert (12) only need be removed and replaced to change the configuration of an outer surface of a component (14) produced by the system, the cost savings is significant in contrast with conventional systems in which the die would have to be reworked. The die cast system (10) may also include an inner liner (12) formed from first end and second end sub-inner liners (20, 22), whereby the first end sub-inner liner (20) may be from a first material that is less compliant than a material forming the second end sub-inner liner (22) enabling more intricate cooling systems to be created by the second end sub-inner liner (22).

Description

DIE CAST SYSTEM FOR FORMING A
COMPONENT USABLE IN A GAS TURBINE ENGINE
FIELD OF THE INVENTION
This invention is directed generally to die cast systems, and more particularly to manufacturing methods for turbine airfoils usable in turbine engines.
BACKGROUND
Turbine blade airfoils typically have internal cooling systems formed from a plurality of cooling channels, as shown in Figure 2 and 3. To form these cooling channels inside of a blade, a casting mold is often used and includes an internal ceramic core and external ceramic shell. The ceramic core, as shown in Figure 1 , is manufactured to include detail features on the core die surface in order to form efficient cooling devices inside the blade casting. The core dies typically used to form cores are most often formed from hard steel, which are expensive to
manufacture. The core die surfaces are typically in direct contact with the ceramic core material during the high pressure injection process. The core die will wear out after sufficient injections and lead to non-conforming casting. To maintain accurate casting dimensions, the core die needs to be reworked or replaced when a core die becomes worn, which is an expensive endeavor. Even a small improvement on an internal surface requires that a completely new die be made. Thus, a need exists for a more robust, less expensive system.
SUMMARY OF THE INVENTION
A die cast system having an inner liner insert that enables the configuration of a component produced by the system to be easily changed by changing the inner liner insert without having to rework the die housing is disclosed. Because the inner liner insert only need be removed and replaced to change the configuration of an outer surface of a component produced by the system, the cost savings is significant in contrast with conventional systems in which the die would have to be reworked. The die cast system may also include an inner liner formed from first and second end sub-inner liners, whereby the first end sub-inner liner may be from a first material that is less compliant than a material forming the second end sub-inner liner enabling more intricate cooling systems to be created by the second end sub-inner liner that is formed from a more compliant material.
In at least one embodiment, the die cast system may include a die housing having one or more inner chambers forming an insert receiving chamber and one or more inner liners positioned within the insert receiving chamber of the inner chamber of the die housing. The inner liner may have an inner surface defining boundaries useful to form an inner surface of a turbine component, whereby the inner liner may be formed via a selective laser melting process. The inner liner may be formed from a first side sub-inner liner forming a first side of the turbine component and a second side sub-inner liner forming a second side of the turbine component. The first side sub-inner liner may form an outer wall of a suction side of an airfoil usable in a gas turbine engine and may include at least one cavity on an inner side of the outer wall that is configured to form at least a portion of an internal airfoil cooling system. The second side sub-inner liner may form an outer wall of a pressure side of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the outer wall that is configured to form at least a portion of an internal airfoil cooling system.
In at least one embodiment, the inner liner may be formed from a non- ceramic, flexible material. The inner liner may be formed from a different material than the die housing. The die housing may be formed from a first sub-die housing and a second sub-die housing having a mateable interface positioned therebetween such that the first and second sub-die housings are mateable at the mateable interface.
In another embodiment, the inner liner may be formed from a first end sub- inner liner forming a first end of the turbine component and a second end sub-inner liner forming a second end of the turbine component. The first end sub-inner liner may be formed from a first material that is less compliant than a material forming the second end sub-inner liner. The second end sub-inner liner being more compliant may be used to form intricate aspects to the internal cooling system. The first end sub-inner liner may be configured to form a leading edge of an airfoil usable in a turbine engine and second end sub-inner liner is configured to form a trailing edge of the airfoil usable in the turbine engine.
In at least one embodiment, the first end sub-inner liner may be formed from a first end, first side sub-inner liner and a first end, second side sub-inner liner. The first end, first side sub-inner liner may form a suction side outer wall of an upstream portion of a suction side of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the suction side outer wall that is configured to form at least a portion of an internal airfoil cooling system. The first end, second side sub-inner liner may form a pressure side outer wall of a pressure side of the upstream portion of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the pressure side outer wall that is configured to form at least a portion of an internal airfoil cooling system.
The second end sub-inner liner may be formed from a second end, first side sub-inner liner and a second end, second side sub-inner liner. The second end, first side sub-inner liner may form a suction side outer wall of a downstream portion of a suction side of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the suction side outer wall that is configured to form at least a portion of an internal airfoil cooling system. The second end, second side sub-inner liner may form a pressure side outer wall of a pressure side of the downstream portion of an airfoil usable in a gas turbine engine and may include one or more cavities on an inner side of the pressure side outer wall that is configured to form at least a portion of an internal airfoil cooling system.
A method of forming a turbine component is disclosed. The method may include injecting a ceramic material into at least one inner cavity formed within a composite die cast system, wherein the die cast system may be formed from a die housing having one or more inner chambers forming an insert receiving chamber and one or more inner liners positioned within the insert receiving chamber of the inner chamber of the die housing. The inner liner may have an inner surface defining boundaries useful to form an inner surface of a turbine component. The inner liner may be formed via a selective laser melting process. The method may also include removing the die cast system thereby revealing a ceramic core. The method may include firing the ceramic core, placing the ceramic core within an inner cavity formed by an inner surface of a wax die, and injecting wax into one or more openings formed between the ceramic core and the inner surface of the wax die. The method may also include removing the wax die to reveal a wax component, coating the wax component with a ceramic coating to form a ceramic shell with a ceramic core positioned therein and removing the wax component within the ceramic coating leaving one or more cavities within the ceramic coating. The method may also include filling the cavity within the ceramic coating with a molten metal and removing the ceramic shell and the ceramic core to form a cast
component.
An advantage of the composite die cast system is that because the inner liner insert only need be removed and replaced to change the configuration of an inner surface of a component produced by the system, a significant cost savings is captured in contrast with conventional systems in which the die would have to be reworked.
Another advantage of the hybrid die cast system is that use of the hybrid die cast system will reduce time and effort required to create a core die in a conventional casting process.
Yet another advantage of the hybrid die cast system is that the inner liner may be formed from different portions formed from different materials, thereby enabling portions of the inner liner proximate to aspects of the core where intricate aspects of an internal cooling system are located, to be formed from more compliant material enabling those intricate aspects of the internal cooling system to be formed.
These and other embodiments are described in more detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the presently disclosed invention and, together with the description, disclose the principles of the invention.
Figure 1 is a perspective view of a conventionally formed core.
Figure 2 is a cross-sectional view of two adjacent conventional turbine airfoils. Figure 3 is a cross-sectional view of a conventional turbine airfoil with an internal cooling system.
Figure 4 is a cross-sectional view of an inner liner of the die cast system.
Figure 5 is a cross-sectional view of an inner liner positioned within a die housing of the die cast system.
Figure 6 is a cross-sectional view of a ceramic material injected within the inner liner positioned within a die housing of the die cast system.
Figure 7 is a cross-sectional view of a ceramic core.
Figure 8 is a cross-sectional view of a ceramic core after firing.
Figure 9 is a cross-sectional view of a ceramic core after firing placed in a wax die and wax injected into the openings between the ceramic core and the wax die.
Figure 10 is a cross-sectional view of a wax pattern with the ceramic core and with the wax die removed.
Figure 1 1 is a cross-sectional view of the wax pattern with a ceramic shell formed around the wax pattern.
Figure 12 is a cross-sectional view of the ceramic shell and ceramic core with the wax pattern removed.
Figure 13 is a cross-sectional view of the ceramic shell and ceramic core with molten metal in the ceramic casting mold.
Figure 14 is a casting of a component with the ceramic shell and ceramic core removed.
Figure 15 is a flow chart of a method of forming a casting component, such as, but not limited to, an airfoil from cast metal.
Figure 16 is a cross-sectional view of an alternative inner liner of the die cast system.
Figure 17 is a cross-sectional view of the alternative inner liner of Figure 16 positioned within a die housing of the die cast system.
Figure 18 is a cross-sectional view of a ceramic material injected within the alternative inner liner of Figure 16 positioned within a die housing of the die cast system.
Figure 19 is a cross-sectional view of a ceramic core.
Figure 20 is a cross-sectional view of a ceramic core after firing. Figure 21 is a cross-sectional view of a ceramic core after firing placed in a wax die and wax injected into the openings between the ceramic core and the wax die.
Figure 22 is a cross-sectional view of a wax pattern with the ceramic core and with the wax die removed.
Figure 23 is a cross-sectional view of the wax pattern with a ceramic shell formed around the wax pattern.
Figure 24 is a cross-sectional view of the ceramic shell and ceramic core with the wax pattern removed.
Figure 25 is a cross-sectional view of the ceramic shell and ceramic core with molten metal in the ceramic casting mold.
Figure 26 is a casting of a component with the ceramic shell and ceramic core removed.
Figure 27 is a perspective view of a turbine airfoil formed with the die cast system of Figures 4-14 and 16-26 and via the method of using the system shown in Figure 15.
Figure 28 is a cross-sectional view of the turbine airfoil taken along section line 28-28 in Figure 27. DETAILED DESCRIPTION OF THE INVENTION
As shown in Figures 4-28, a die cast system 10 having an inner liner insert 12 that enables the configuration of a component 14 produced by the system 10 to be easily changed by changing the inner liner insert 12 without having to rework the die housing 16 is disclosed. Because the inner liner insert 12 only need be removed and replaced to change the configuration of an inner surface 18 of a component 14 produced by the system 10, the cost savings is significant in contrast with
conventional systems in which the die would have to be reworked. The die cast system 10 may also include an inner liner 12 formed from first and second end sub- inner liners 20, 22, whereby the first end sub-inner liner 20 may be from a first material that is less compliant than a material forming the second end sub-inner liner 22 enabling more intricate cooling systems to be created by the second end sub- inner liner 22, which is more compliant than the first end inner liner 20. In at least one embodiment, the die cast system 10 may include a die housing 16 may have one or more inner chambers 23 forming an insert receiving chamber 24. The die cast system 10 may also include one or more inner liners 12 positioned within the insert receiving chamber 24 of the inner chamber 24 of the die housing 16. The inner liner 12 may have an inner surface 26 defining boundaries useful to form an inner surface 18 of a turbine component 14. In at least one embodiment, the inner surface 26 of the inner liner 12 may be configured to form an airfoil 138 usable in a gas turbine engine. The airfoil 138 may be formed from a generally elongated, hollow airfoil 140 having a leading edge 142 on an opposite side from a trailing edge 144 and separated by a concave pressure side 146 and a convex suction side 148. The generally elongated, hollow airfoil 60 may have one or more film cooling holes 150 at one or more of the leading edge 142 forming a showerhead, concave pressure side 146, the convex suction side 148 or the trailing edge 144, or any combination thereof.
In at least one embodiment, the inner liner 12 may be formed via a selective laser melting process, with a material such as, but not limited to, iron. The inner liner 12 may be formed from a first side sub-inner liner 30 forming a first side 32 of the turbine component 14 and a second side sub-inner liner 34 forming a second side 36 of the turbine component 14. In at least one embodiment, as shown in Figure 4-6, the first side sub-inner liner 30 may be formed from an outer wall 38 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48. The second side sub-inner liner 34 may form an outer wall 50 of a pressure side 52 of the airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the outer wall 50 that is configured to form at least a portion of an internal airfoil cooling system 48. In at least one embodiment, as shown in Figures 4-6, the first side sub-inner liner 30 and the second side sub-inner liner 34 may together form a plurality of inner cavities 44 forming the internal airfoil cooling system 48.
In at least one embodiment, the inner liner 12 may be formed from a non- ceramic material, such as, but not limited to, iron, or another appropriate material. The inner liner 12 may be formed from a different material than the die housing 16. The die housing 16 may be formed from a first sub-die housing 58 and a second sub-die housing 60 having a mateable interface 62 positioned therebetween such that the first and second sub-die housings 58, 60 are mateable at the mateable interface 62.
In at least one embodiment, as shown in Figures 16-18, the inner liner 12 may be formed from a first end sub-inner liner 20 forming a first end 64 of the turbine component 14 and a second end sub-inner liner 22 forming a second end 66 of the turbine component 14. The first end sub-inner liner 20 may be formed from a first material that is less compliant than a material forming the second end sub-inner liner 22. As such, that less compliant material may be used to form intricate aspects of the internal cooling system 48. In at least one embodiment, the second end sub- inner liner 22 form from the less compliant material may be formed by processes employed by Mikro Systems of Charlottesville, VA. The first end sub-inner liner 20 may be configured to form a leading edge 70 of an airfoil shaped core 42 usable in a turbine engine, and second end sub-inner liner 22 may be configured to form a trailing edge 72 of the airfoil shaped core 42 usable in the turbine engine.
In at least one embodiment, as shown in Figures 16-18, the first end sub-inner liner 20 may be formed from a first end, first side sub-inner liner 74 and a first end, second side sub-inner liner 76. The first end, first side sub-inner liner 74 may form a suction side outer wall 38 of an upstream portion 78 of a suction side 40 of an airfoil shaped core 42. The first end, first side sub-inner liner 74 may include one or more cavities 44 on an inner side 46 of the suction side outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48. The first end, second side sub-inner liner 76 may form a pressure side outer wall 50 of a pressure side 52 of the upstream portion 78 of an airfoil shaped core 42. The first end, second side sub-inner liner 76 may include one or more cavities 44 on an inner side 56 of the pressure side outer wall 50 that is configured to form at least a portion of the internal airfoil cooling system 48.
Similarly, the second end sub-inner liner 22 may be formed from a second end, first side sub-inner liner 80 and a second end, second side sub-inner liner 82. The second end, first side sub-inner liner 80 may form a suction side outer wall 38 of a downstream portion 84 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the suction side outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48. The second end, second side sub-inner liner 82 may form a pressure side outer wall 50 of a pressure side 52 of the downstream portion 84 of the airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the pressure side outer wall 50 that is configured to form at least a portion of the internal airfoil cooling system 48.
As shown in Figure 15, a method 100 of forming a turbine component 14 may include forming a ceramic core die 90 at 101 and Figures 4 and 16 via a selective laser melting process. The die 90 may be positioned within a die housing 16 at 102 and Figures 5 and 17. The method 100 may also include injecting a ceramic material 98 at 103 and Figures 6 and 18 into one or more inner cavities 44 formed within a die cast system 10 in which the die cast system 10 may be formed from a die housing 16 having one or more inner chambers 23 forming an insert receiving chamber 24. The die cast system 10 may also include one or more inner liners 12 positioned within the insert receiving chamber 24 of the inner chamber 23 of the die housing 16. The inner liner 12 may have an inner surface 26 defining boundaries useful to form an inner surface 18 of a turbine component 14. The inner liner 12 may be formed via a selective laser melting process. The method may include removing the die cast system 10 at 104 and Figures 7 and 19 thereby revealing a ceramic core 90.
The method may also include firing the ceramic core 90 at 106 and Figures 8 and 20 and placing the ceramic core 90 at 108 within an inner cavity 92 formed by an inner surface 94 of a wax die 96. The method may also include injecting wax 88 at 1 10 and Figures 9 and 21 into at least opening 92 formed between the ceramic core 90 and the inner surface 94 of the wax die 96. The method may include removing the wax die 96 at 1 12 and Figures 10 and 22 to reveal a wax component 86 and coating the wax component 86 at 1 14 and Figures 1 1 and 23 with a ceramic coating 1 16 to form a ceramic shell 1 18 with a ceramic core 90 positioned therein. The method may include removing the wax component 86 at 120 and Figures 12 and 24 within the ceramic coating 1 16 leaving one or more cavities 122 within the ceramic coating 1 16. The method may include filling the cavity 122 at 124 and Figures 13 and 25 within the ceramic coating 1 16 with a molten metal and removing the ceramic shell 1 18 and the ceramic core 90 at 126 and Figures 14 and 26 to form a cast component 14.
The step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the inner liner 12 is formed from a first side sub-inner liner 30 forming a first side 32 of the turbine component 14 and a second side sub-inner liner 34 forming a second side 36 of the turbine component 14. The step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the first side sub-inner liner 30 may form an outer wall 38 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48. The second side sub-inner liner 34 may form an outer wall 50 of a pressure side 52 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the outer wall 50 that is configured to form at least a portion of an internal airfoil cooling system 48.
The step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the inner liner 12 may be formed from a first end sub-inner liner 20 forming a first end 64 of the turbine component 14 and a second end sub- inner liner 22 forming a second end 66 of the turbine component 14, wherein the first end sub-inner liner 20 may be formed from a first material having a less compliant than a material forming the second end sub-inner liner 22.
The step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the first end sub-inner liner 20 may be formed from a first end, first side sub-inner liner 74 and a first end, second side sub-inner liner 76, and wherein the first end, first side sub-inner liner 74 may form a suction side outer wall 38 of an upstream portion 78 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the suction side outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48. The first end, second side sub-inner liner 76 may form a pressure side outer wall 50 of a pressure side 52 of the upstream portion 78 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the pressure side outer wall 50 that is configured to form at least a portion of an internal airfoil cooling system 48.
The step of injection a ceramic material at 102 may include injecting a ceramic material into at least one inner cavity 122 formed within the composite die cast system 10, wherein the second end sub-inner liner 22 may be formed from a second end, first side sub-inner liner 80 and a second end, second side sub-inner liner 82, and wherein the second end, first side sub-inner liner 80 may form a suction side outer wall 38 of a downstream portion 84 of a suction side 40 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 46 of the suction side outer wall 38 that is configured to form at least a portion of an internal airfoil cooling system 48. The second end, second side sub-inner liner 82 may form a pressure side outer wall 50 of a pressure side 52 of the downstream portion 84 of an airfoil shaped core 42 and may include one or more cavities 44 on an inner side 56 of the pressure side outer wall 50 that is configured to form at least a portion of an internal airfoil cooling system 48.
The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this invention. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this invention.

Claims

CLAIMS I claim:
1 . A die cast system (10), characterized in that:
a die housing (16) having at least one inner chamber (23) forming an insert receiving chamber (24);
at least one inner liner (12) positioned within the insert receiving chamber (24) of the at least one inner chamber (23) of the die housing (16), wherein the at least one inner liner (12) has an inner surface (18) defining boundaries useful to form an inner surface (26) of a turbine component (14); and
wherein the inner liner (12) is formed via a selective laser melting process.
2. The die cast system (10) of claim 1 , characterized in that the at least one inner liner (12) is formed from a first side sub-inner liner (30) forming a first side (32) of the turbine component (14) and a second side sub-inner liner (34) forming a second side (36) of the turbine component (14).
3. The die cast system (10) of claim 2, characterized in that the first side sub-inner liner (30) forms an outer wall (38) of a suction side (40) of an airfoil usable in a gas turbine engine and includes at least one cavity (44) on an inner side (46) of the outer wall (38) that is configured to form at least a portion of an internal airfoil cooling system (48), and wherein the second side sub-inner liner (34) forms an outer wall (50) of a pressure side (52) of an airfoil usable in a gas turbine engine and includes at least one cavity (44) on an inner side (56) of the outer wall (50) that is configured to form at least a portion of an internal airfoil cooling system (48).
4. The die cast system (10) of claim 1 , characterized in that the at least one inner liner (12) is formed from a non-ceramic material.
5. The die cast system (10) of claim 1 , characterized in that the at least one inner liner (12) is formed from a different material than the die housing (16).
6. The die cast system (10) of claim 1 , characterized in that the die housing (16) is formed from a first sub-die housing (58) and a second sub-die housing (60) having a mateable interface (62) positioned therebetween such that the first and second sub-die housings (58, 60) are mateable at the mateable interface (62).
7. The die cast system (10) of claim 1 , characterized in that the inner liner (12) is formed from a first end sub-inner liner (20) forming a first end (64) of the turbine component (14) and a second end sub-inner liner (22) forming a second end (66) of the turbine component (14).
8. The die cast system (10) of claim 7, characterized in that the first end sub-inner liner (20) is formed from a first material that is less compliant than a material forming the second end sub-inner liner (22).
9. The die cast system (10) of claim 7, characterized in that the first end sub-inner liner (20) is configured to form a leading edge (70) of an airfoil usable in a turbine engine and second end sub-inner liner (22) is configured to form a trailing edge (72) of the airfoil usable in the turbine engine.
10. The die cast system (10) of claim 8, characterized in that the first end sub-inner liner (20) is formed from a first end, first side sub-inner liner (74) and a first end, second side sub-inner liner (76).
1 1 . The die cast system (10) of claim 10, characterized in that the first end, first side sub-inner liner (74) forms a suction side outer wall (38) of an upstream portion (78) of a suction side (40) of an airfoil usable in a gas turbine engine and includes at least one cavity (44) on an inner side (46) of the suction side outer wall (38) that is configured to form at least a portion of an internal airfoil cooling system (48), and wherein the first end, second side sub-inner liner (76) forms a pressure side outer wall (50) of a pressure side (52) of the upstream portion (78) of an airfoil usable in a gas turbine engine and includes at least one cavity (44) on an inner side (56) of the pressure side outer wall (50) that is configured to form at least a portion of an internal airfoil cooling system (48).
12. The die cast system (10) of claim 8, characterized in that the second end sub-inner liner (22) is formed from a second end, first side sub-inner liner (80) and a second end, second side sub-inner liner (82).
13. The die cast system (10) of claim 12, characterized in that the second end, first side sub-inner liner (80) forms a suction side outer wall (38) of a
downstream portion (84) of a suction side (40) of an airfoil usable in a gas turbine engine and includes at least one cavity (44) on an inner side 946) of the suction side outer wall (38) that is configured to form at least a portion of an internal airfoil cooling system (48), and wherein the second end, second side sub-inner liner (82) forms a pressure side outer wall (50) of a pressure side (52) of the downstream portion (84) of an airfoil usable in a gas turbine engine and includes at least one cavity (44) on an inner side (56) of the pressure side outer wall (50) that is configured to form at least a portion of an internal airfoil cooling system (48).
EP14796598.2A 2014-10-15 2014-10-15 Die cast system for forming a component usable in a gas turbine engine Active EP3206814B1 (en)

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EP1930096A1 (en) * 2006-12-07 2008-06-11 Siemens Aktiengesellschaft Methof of manufacturing casting pattern for investment casting of parts containing at least one hollow portion
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EP3206814B1 (en) 2020-07-01

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