JP2017148864A - 内部に画成された触媒作用を受ける内部通路を有する部品を形成するための方法及びアセンブリ - Google Patents
内部に画成された触媒作用を受ける内部通路を有する部品を形成するための方法及びアセンブリ Download PDFInfo
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- B22C9/06—Permanent moulds for shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D25/00—Special casting characterised by the nature of the product
- B22D25/02—Special casting characterised by the nature of the product by its peculiarity of shape; of works of art
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- 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
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- 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
- B22C9/101—Permanent cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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- 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
- B22D19/0072—Casting in, on, or around objects which form part of the product for making objects with integrated channels
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
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- F23R3/40—Continuous combustion chambers using liquid or gaseous fuel characterised by the use of catalytic means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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Abstract
【解決手段】内部に内部通路(82)が画成された部品(80)を形成する方法(2000)は、鋳型(300)に対して被覆コア(310)を配置する工程(2002)を含む。被覆コアは、少なくとも第1の材料(322)及び第1の触媒(362)から形成された中空構造体(320)と、中空構造体内に配された内側コア(324)とを含む。方法は、また、溶融状態の部品材料(78)を鋳型キャビティ(304)に導入する工程(2004)と、キャビティ内の部品材料を冷却して部品を形成する工程(2006)とを含む。内側コアは、部品内に内部通路を画成する。
【選択図】図1
Description
[実施態様1]
内部に内部通路(82)が画成された部品(80)を形成する方法であって、
鋳型(300)に対して被覆コア(310)を配置する工程であって、被覆コア(310)が、少なくとも第1の材料(322)及び第1の触媒(362)から形成された中空構造体(320)と、中空構造体(320)内に配された内側コア(324)とを含んでいる、工程と、
溶融状態の部品材料(78)を鋳型(300)のキャビティ(304)に導入する工程と、
キャビティ(304)内の部品材料(78)を冷却して部品(80)を形成する工程であって、内側コア(324)は、部品(80)内に内部通路(82)を画成する、工程と、
を含む方法。
[実施態様2]
部品材料(78)をキャビティ(304)に導入する工程は、部品(80)が形成された後に、内側コア(324)に近接する第1の触媒(362)の濃度が、内部壁(302)のうち部品(80)内の内部通路(82)を画成する少なくとも一部分に沿って、第1の触媒(362)に伴う触媒作用効果を確立するのに十分となるように、部品材料(78)を導入する工程を含む、実施態様1に記載の方法。
[実施態様3]
部品材料(78)をキャビティ(304)に導入する工程は、部品(80)が形成された後に、第1の触媒(362)が、内部壁(302)のうち部品(80)内の内部通路(82)を画成する少なくとも一部分にライニングを施すように、部品材料(78)を導入する工程を含む、実施態様1に記載の方法。
[実施態様4]
被覆コア(310)を配置する工程は、被覆コア(310)を配置する工程を含み、第1の触媒(362)は、(i)改質触媒、(ii)プロトン酸、(iii)アルミナ、及び(iv)酸化バナジウムのうちの1つから選択される、実施態様1に記載の方法。
[実施態様5]
被覆コア(310)を配置する工程は、被覆コア(310)を配置する工程を含み、第1の触媒(362)は、第1の材料(322)の半径方向内側にある、中空構造体(320)の内側部分(360)のうち1以上の既定の第1の長手方向部分(354)に延在する、実施態様1に記載の方法。
[実施態様6]
被覆コア(310)を配置する工程は、第1の材料(322)、第1の触媒(362)、及び第2の触媒(382)から形成された中空構造体(320)を含む被覆コア(310)を配置する工程を含み、第2の触媒(382)は、第1の材料(322)の半径方向内側にある、中空構造体(320)の内側部分(360)のうち1以上の既定の第2の長手方向部分(356)に延在する、実施態様5に記載の方法。
[実施態様7]
中空構造体(320)の内側部分(360)は、第1の触媒(362)から少なくとも部分的に形成され、内側部分(360)は、内部通路(82)の1以上の内部通路特徴(98)を画成するように形作られ、部品材料(78)をキャビティ(304)に導入する工程は、部品(80)が形成された後に、第1の触媒(362)が1以上の内部通路特徴(98)の少なくとも一部分を形成するように、部品材料(78)を導入する工程を含む、実施態様1に記載の方法。
[実施態様8]
中空構造体(320)は、内側コア(324)を長手方向に延在する複数のチャンバ(392)に区分する1以上のストラット(390)を含み、第1の触媒(362)は、内側コア(324)に隣接する1以上のストラット(390)に沿って配され、部品材料(78)をキャビティ(304)に導入する工程は、部品(80)が形成された後に、内側コア(324)の複数のチャンバ(392)の各々が内部通路(82)の対応するチャンバ(392)を画成するように、部品材料(78)を導入する工程を含む、実施態様1に記載の方法。
[実施態様9]
被覆コア(310)を配置する工程は、付加製造法を用いて各々形成された複数の層(366、368、370)を含む中空構造体(320)を含む被覆コア(310)を配置する工程を含む、実施態様1に記載の方法。
[実施態様10]
付加製造法を用いて中空構造体(320)を形成する工程をさらに含む、実施態様1に記載の方法。
[実施態様11]
付加製造法を用いることは、第1の材料(322)及び第1の触媒(362)の各々を交互に堆積させて、第1の材料(322)及び第1の触媒(362)の規定の分布を中空構造体(320)の複数の層(366、368、370)の各々に作り出すことを含む、実施態様10に記載の方法。
[実施態様12]
付加製造法を用いることは、直接金属レーザ溶融(DMLM)法、直接金属レーザ焼結(DMLS)法、選択レーザ焼結(SLS)法、電子ビーム溶融(EBM)法、選択レーザ溶融法(SLM)、及びロボキャスティング押出式付加法のうちの少なくとも1つを用いることを含む、実施態様10に記載の方法。
[実施態様13]
内部に内部通路(82)が画成された部品(80)を形成する際に用いるための鋳型アセンブリ(301)であって、
内部に鋳型キャビティ(304)を画成する鋳型(300)と、
鋳型(300)に対して配置された被覆コア(310)であって、
少なくとも第1の材料(322)及び第1の触媒(362)から形成された中空構造体(320)と、
中空構造体(320)内に配され、溶融状態の部品材料(78)が鋳型キャビティ(304)に導入され冷却されて部品(80)を形成するときに部品(80)内の内部通路(82)を画成するように配置される、内側コア(324)とを備える被覆コア(310)と、
を備える、鋳型アセンブリ(301)。
[実施態様14]
第1の触媒(362)は、(i)改質触媒、(ii)プロトン酸、(iii)アルミナ、及び(iv)酸化バナジウムのうちの1つである、実施態様13に記載の鋳型アセンブリ(301)。
[実施態様15]
第1の触媒(362)は、第1の材料(322)の半径方向内側にある、中空構造体(320)の内側部分(360)のうち1以上の既定の第1の長手方向部分(354)に延在する、実施態様13に記載の鋳型アセンブリ(301)。
[実施態様16]
中空構造体(320)は、第1の材料(322)、第1の触媒(362)、及び第2の触媒(382)から形成され、第2の触媒(382)は、第1の材料(322)の半径方向内側にある、中空構造体(320)の内側部分(360)の1以上の既定の第2の長手方向部分(356)に延在する、実施態様13に記載の鋳型アセンブリ(301)。
[実施態様17]
中空構造体(320)は、第1の触媒(362)から少なくとも部分的に形成された内側部分(360)を備え、内側部分(360)は、部品(80)が形成されたときに内部通路(82)の1以上の内部通路特徴(98)を画成するように形作られる、実施態様13に記載の鋳型アセンブリ(301)。
[実施態様18]
中空構造体(320)は、内側コア(324)を長手方向に延在する複数のチャンバ(392)に区分する1以上のストラット(390)をさらに備える、実施態様13に記載の鋳型アセンブリ(301)。
[実施態様19]
第1の触媒(362)は、内側コア(324)に隣接する1以上のストラット(390)に沿って配される、実施態様18に記載の鋳型アセンブリ(301)。
[実施態様20]
第2の触媒(382)が、内側コア(324)に隣接する1以上のストラット(390)に沿って配される、実施態様18に記載の鋳型アセンブリ(301)。
[実施態様21]
中空構造体(320)は、第1の材料(322)、第1の触媒(362)、及び第2の材料(372)から形成され、第2の材料(372)は、第1の触媒(362)による触媒作用を受ける反応の促進物質であるように選択される、実施態様13に記載の鋳型アセンブリ(301)。
[実施態様22]
中空構造体(320)は、付加製造法を用いて各々形成された複数の層(366、368、370)を備える、実施態様13に記載の鋳型アセンブリ(301)。
12 吸気セクション
14 圧縮機セクション
16 燃焼機セクション
18 タービンセクション
20 排気セクション
22 ロータシャフト
24 燃焼機
36 ケーシング
40 圧縮機ブレード
42 圧縮機静翼
70 ロータブレード
72 タービン静翼
78 部品材料
80 部品
82 二元触媒内部通路
88 第1の端部
90 第2の端部
98 内部通路特徴
100 内部壁
300 鋳型
301 鋳型アセンブリ
302 内部壁
304 鋳型キャビティ
306 鋳型材料
310 被覆コア
312 先端部分
314 先端部分
315 部分
316 根元部分
318 根元部分
320 中空構造体
322 第1の材料
324 内側コア
326 内側コア材料
328 壁厚
330 固有幅
331 相補的特徴
334 凹んだ特徴
339 螺旋溝構造
341 螺旋突起
350 第1の端部
352 第2の端部
354 第1の長手方向部分
356 第2の長手方向部分
360 内側部分
362 第1の触媒
366 層
368 層
370 層
372 第2の材料
380 外側壁
382 第2の触媒
390 ストラット
392 チャンバ
394 第1の端部
396 第2の端部
Claims (10)
- 内部に内部通路が画成された部品を形成する方法であって、
鋳型に対して被覆コアを配置する工程であって、被覆コアが、少なくとも第1の材料及び第1の触媒から形成された中空構造体と、中空構造体内に配された内側コアとを含んでいる、工程と、
溶融状態の部品材料を鋳型のキャビティに導入する工程と、
キャビティ内の部品材料を冷却して部品を形成する工程であって、内側コアが、部品内に内部通路を画成する、工程と、
を含む方法。 - 部品材料をキャビティに導入する工程は、部品が形成された後に、内側コアに近接する第1の触媒の濃度が、内部壁のうち部品内の内部通路を画成する少なくとも一部分に沿って、第1の触媒に伴う触媒作用効果を確立するのに十分となるように、部品材料を導入する工程を含む、請求項1に記載の方法。
- 中空構造体の内側部分は、第1の触媒から少なくとも部分的に形成され、内側部分は、内部通路の1以上の内部通路特徴を画成するように形作られ、部品材料をキャビティに導入する工程は、部品が形成された後に、第1の触媒が1以上の内部通路特徴の少なくとも一部分を形成するように、部品材料を導入する工程を含む、請求項1に記載の方法。
- 中空構造体は、内側コアを長手方向に延在する複数のチャンバに区分する1以上のストラットを含み、第1の触媒は、内側コアに隣接する1以上のストラットに沿って配され、部品材料をキャビティに導入する工程は、部品が形成された後に、内側コアの複数のチャンバの各々が内部通路の対応するチャンバを画成するように、部品材料を導入する工程を含む、請求項1に記載の方法。
- 付加製造法を用いて中空構造体を形成する工程をさらに含む、請求項1に記載の方法。
- 内部に内部通路が画成された部品を形成する際に用いるための鋳型アセンブリであって、
内部に鋳型キャビティを画成する鋳型と、
鋳型に対して配置された被覆コアであって、少なくとも第1の材料及び第1の触媒から形成された中空構造体と、中空構造体内に配置される内側コアであって、溶融状態の部品材料を鋳型キャビティ内に導入して冷却して部品を形成する際に部品内の内部通路を画成するように配置される内側コアとを備える被覆コアと
を備える、鋳型アセンブリ。 - 第1の触媒は、第1の材料の半径方向内側にある、中空構造体の内側部分のうち1以上の既定の第1の長手方向部分に延在する、請求項6に記載の鋳型アセンブリ。
- 中空構造体は、第1の触媒から少なくとも部分的に形成された内側部分を備え、内側部分は、部品が形成されたときに内部通路の1以上の内部通路特徴を画成するように形作られる、請求項6に記載の鋳型アセンブリ。
- 中空構造体は、内側コアを長手方向に延在する複数のチャンバに区分する1以上のストラットをさらに備える、請求項6に記載の鋳型アセンブリ。
- 中空構造体は、付加製造法を用いて各々形成された複数の層を備える、請求項6に記載の鋳型アセンブリ。
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