JP2020515414A - 浮動する先端プレナムを有する一体式コア−シェル構造 - Google Patents
浮動する先端プレナムを有する一体式コア−シェル構造 Download PDFInfo
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- JP2020515414A JP2020515414A JP2019531725A JP2019531725A JP2020515414A JP 2020515414 A JP2020515414 A JP 2020515414A JP 2019531725 A JP2019531725 A JP 2019531725A JP 2019531725 A JP2019531725 A JP 2019531725A JP 2020515414 A JP2020515414 A JP 2020515414A
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- 239000011258 core-shell material Substances 0.000 title abstract description 40
- 238000007667 floating Methods 0.000 title description 3
- 238000010276 construction Methods 0.000 title 1
- 239000000919 ceramic Substances 0.000 claims abstract description 79
- 238000001816 cooling Methods 0.000 claims abstract description 59
- 238000005266 casting Methods 0.000 claims abstract description 34
- 238000002386 leaching Methods 0.000 claims abstract description 9
- 238000000034 method Methods 0.000 claims description 60
- 238000004519 manufacturing process Methods 0.000 claims description 34
- 239000007788 liquid Substances 0.000 claims description 8
- 229910001338 liquidmetal Inorganic materials 0.000 claims description 6
- 238000005304 joining Methods 0.000 claims description 4
- 230000001678 irradiating effect Effects 0.000 claims description 2
- 239000000126 substance Substances 0.000 claims 3
- 238000005058 metal casting Methods 0.000 abstract description 3
- 239000013589 supplement Substances 0.000 abstract 1
- 239000000463 material Substances 0.000 description 29
- 230000008569 process Effects 0.000 description 16
- 239000002184 metal Substances 0.000 description 12
- 229910052751 metal Inorganic materials 0.000 description 12
- 238000002156 mixing Methods 0.000 description 12
- 229910000601 superalloy Inorganic materials 0.000 description 9
- 238000005495 investment casting Methods 0.000 description 8
- 239000000843 powder Substances 0.000 description 8
- 238000007639 printing Methods 0.000 description 7
- 238000013461 design Methods 0.000 description 5
- 238000012545 processing Methods 0.000 description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 230000007246 mechanism Effects 0.000 description 3
- 239000011800 void material Substances 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 230000004913 activation Effects 0.000 description 2
- 238000005219 brazing Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005553 drilling Methods 0.000 description 2
- 239000012467 final product Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 238000010248 power generation Methods 0.000 description 2
- KUBDPQJOLOUJRM-UHFFFAOYSA-N 2-(chloromethyl)oxirane;4-[2-(4-hydroxyphenyl)propan-2-yl]phenol Chemical compound ClCC1CO1.C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 KUBDPQJOLOUJRM-UHFFFAOYSA-N 0.000 description 1
- 238000010146 3D printing Methods 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000001723 curing Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 229910001026 inconel Inorganic materials 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000000016 photochemical curing Methods 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Classifications
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C13/00—Moulding machines for making moulds or cores of particular shapes
- B22C13/08—Moulding machines for making moulds or cores of particular shapes for shell moulds or shell cores
-
- 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
-
- 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
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
-
- 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
- B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
- B22D27/045—Directionally solidified castings
-
- 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
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C64/124—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified
- B29C64/129—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask
- B29C64/135—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using layers of liquid which are selectively solidified characterised by the energy source therefor, e.g. by global irradiation combined with a mask the energy source being concentrated, e.g. scanning lasers or focused light sources
-
- 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
- B33Y10/00—Processes of additive manufacturing
-
- 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
- B33Y80/00—Products made by additive manufacturing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/16—Form or construction for counteracting blade vibration
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/0037—Production of three-dimensional images
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/757—Moulds, cores, dies
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Ceramic Engineering (AREA)
- General Engineering & Computer Science (AREA)
- General Physics & Mathematics (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Mold Materials And Core Materials (AREA)
- Casting Devices For Molds (AREA)
Abstract
Description
Claims (20)
- セラミックの型を製造する方法であって、
(a)加工物の硬化部分を液状セラミックフォトポリマーと接触させること、
(b)前記液状セラミックフォトポリマーに接触する窓を通して前記硬化部分に隣接する前記液状セラミックフォトポリマーの一部を照射すること、
(c)前記未硬化の液状セラミックフォトポリマーから前記加工物を取り出すこと、及び
(d)セラミックの型が形成されるまで工程(a)〜(c)を繰り返すこと
を含み、前記セラミックの型が、主要コア部、コア先端部、及びシェル部を含み、前記コア部と前記シェル部との間に少なくとも1つのキャビティを有し、前記キャビティが、前記セラミックの型の鋳造及び取り外しの際に鋳造部品の前記形状を画定するように適合され、少なくとも1つのセラミック先端フィラメントが前記コア先端部と前記シェル部とを接続している、方法。 - 前記方法が、工程(d)の後に、液状金属を鋳造用の型に注ぎ込み、前記液状金属を凝固させて前記鋳造部品を形成することを含む工程(e)を含む、請求項1に記載の方法。
- 前記方法が、工程(e)の後に、前記鋳造部品から前記型を取り外すことを含む工程(f)を含む、請求項2に記載の方法。
- 前記鋳造部品から前記型を取り外すことが、機械的な力と化学的な浸出の組み合わせを含む、請求項3に記載の方法。
- 前記浸出の少なくとも一部が、前記セラミック先端フィラメントによって形成された前記鋳造部品の先端の穴を通って生じる、請求項4に記載の方法。
- 前記鋳造部品がタービンブレードであり、前記セラミック先端フィラメントが少なくとも2mm2の断面積を有する、請求項1に記載の方法。
- 前記鋳造部品がタービンブレードであり、前記セラミック先端フィラメントが前記先端プレナムに冷却穴のパターンをもたらす、請求項6に記載の方法。
- 前記鋳造部品がタービンブレード又はステータベーンであり、前記セラミックの型が、前記コア部とシェル部とを接合する複数の冷却穴フィラメントを含み、各フィラメントが前記コアとシェルとの間にまたがり、前記冷却穴フィラメントは、前記型を取り出すと、前記タービンブレード又は前記ステータベーンに複数の冷却穴を画定するよう適合される、請求項1に記載の方法。
- 前記冷却穴フィラメントが、0.01〜2mm2の範囲の断面積を有する、請求項8に記載の方法。
- 鋳造部品を製造する方法であって、
セラミック鋳型に液状金属を注入し、前記液状金属を凝固させて前記鋳造部品を形成することであって、前記セラミックの型が、主要コア部、コア先端部、及びシェル部を含み、前記コア部と前記シェル部との間に少なくとも1つのキャビティを有し、前記キャビティが、前記セラミックの型の鋳造及び取り外しの際に鋳造部品の前記形状を画定するように適合され、少なくとも1つのセラミック先端フィラメントが前記コア先端部と前記シェル部とを接続すること、及び
前記鋳造部品から前記セラミック鋳型を取り外すこと
を含む方法。 - 前記鋳造部品から前記セラミック鋳型を取り外すことが、機械的な力と化学的な浸出の組み合わせを含む、請求項10に記載の方法。
- 前記化学的な浸出を除去することがアルカリ性である、請求項11に記載の方法。
- 前記鋳造部品がタービンブレード又はステータベーンである、請求項10に記載の方法。
- 前記鋳造部品がタービンブレード又はステータベーンであり、前記セラミックの型が、前記コア部とシェル部とを接合する複数のフィラメントを含み、各フィラメントが前記コアとシェルとの間にまたがり、前記フィラメントは、前記型を取り出すと、前記タービンブレード又は前記ステータベーンに複数の冷却穴を画定するよう適合される、請求項10に記載の方法。
- 前記冷却穴フィラメントが、0.01〜2mm2の範囲の断面積を有する、請求項14に記載の方法。
- セラミック鋳型であって、
主要コア部、コア先端部、及びシェル部を含み、前記コア部と前記シェル部との間に少なくとも1つのキャビティを有し、前記キャビティが、前記セラミックの型の鋳造及び取り外しの際に鋳造部品の前記形状を画定するように適合され、少なくとも1つのセラミック先端フィラメントが前記コア先端部と前記シェル部とを接続する、セラミック鋳型。 - 前記鋳造部品がタービンブレード又はステータベーンであり、前記セラミックの型が、前記コア部とシェル部とを接合する複数のフィラメントを含み、各フィラメントが前記コアとシェルとの間にまたがり、前記フィラメントは、前記型を取り出すと、前記タービンブレード又は前記ステータベーンに複数の冷却穴を画定するよう適合される、請求項16に記載のセラミック鋳型。
- 前記冷却穴フィラメントが、0.01〜2mm2の範囲の断面積を有する、請求項17に記載のセラミック鋳型。
- 前記セラミックが光重合セラミックである、請求項17に記載のセラミック鋳型。
- 前記セラミックが硬化した光重合セラミックである、請求項17に記載のセラミック鋳型。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/377,711 | 2016-12-13 | ||
US15/377,711 US20180161853A1 (en) | 2016-12-13 | 2016-12-13 | Integrated casting core-shell structure with floating tip plenum |
PCT/US2017/057945 WO2018111408A1 (en) | 2016-12-13 | 2017-10-24 | Integrated casting core-shell structure with floating tip plenum |
Publications (2)
Publication Number | Publication Date |
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JP2020515414A true JP2020515414A (ja) | 2020-05-28 |
JP7006880B2 JP7006880B2 (ja) | 2022-01-24 |
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JP2019531725A Active JP7006880B2 (ja) | 2016-12-13 | 2017-10-24 | 浮動する先端プレナムを有する一体式コア-シェル構造 |
Country Status (6)
Country | Link |
---|---|
US (1) | US20180161853A1 (ja) |
EP (1) | EP3554748B1 (ja) |
JP (1) | JP7006880B2 (ja) |
CN (1) | CN110062673B (ja) |
CA (1) | CA3045620C (ja) |
WO (1) | WO2018111408A1 (ja) |
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US11813669B2 (en) | 2016-12-13 | 2023-11-14 | General Electric Company | Method for making an integrated core-shell structure |
US20180161866A1 (en) | 2016-12-13 | 2018-06-14 | General Electric Company | Multi-piece integrated core-shell structure for making cast component |
US10807154B2 (en) * | 2016-12-13 | 2020-10-20 | General Electric Company | Integrated casting core-shell structure for making cast component with cooling holes in inaccessible locations |
US20180161852A1 (en) * | 2016-12-13 | 2018-06-14 | General Electric Company | Integrated casting core-shell structure with printed tubes for making cast component |
US20180161854A1 (en) * | 2016-12-13 | 2018-06-14 | General Electric Company | Integrated casting core-shell structure |
GB201701365D0 (en) * | 2017-01-27 | 2017-03-15 | Rolls Royce Plc | A ceramic core for an investment casting process |
US11173542B2 (en) | 2017-06-28 | 2021-11-16 | General Electric Company | Additively manufactured casting core-shell mold and ceramic shell with variable thermal properties |
US11192172B2 (en) | 2017-06-28 | 2021-12-07 | General Electric Company | Additively manufactured interlocking casting core structure with ceramic shell |
US10391549B2 (en) | 2017-06-28 | 2019-08-27 | General Electric Company | Additively manufactured casting core-shell hybrid mold and ceramic shell |
US10974312B2 (en) | 2017-06-28 | 2021-04-13 | General Electric Company | Additively manufactured casting core-shell mold with integrated filter and ceramic shell |
US10391670B2 (en) | 2017-06-28 | 2019-08-27 | General Electric Company | Additively manufactured integrated casting core structure with ceramic shell |
CN112916811B (zh) * | 2021-01-22 | 2023-05-16 | 成都航宇超合金技术有限公司 | 带气膜孔的空心涡轮叶片的铸造方法 |
US11739646B1 (en) | 2022-03-31 | 2023-08-29 | General Electric Company | Pre-sintered preform ball for ball-chute with hollow member therein for internal cooling of turbine component |
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2016
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2017
- 2017-10-24 EP EP17794578.9A patent/EP3554748B1/en active Active
- 2017-10-24 CA CA3045620A patent/CA3045620C/en active Active
- 2017-10-24 JP JP2019531725A patent/JP7006880B2/ja active Active
- 2017-10-24 CN CN201780076936.4A patent/CN110062673B/zh active Active
- 2017-10-24 WO PCT/US2017/057945 patent/WO2018111408A1/en unknown
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Also Published As
Publication number | Publication date |
---|---|
EP3554748A1 (en) | 2019-10-23 |
JP7006880B2 (ja) | 2022-01-24 |
CN110062673B (zh) | 2021-11-30 |
CA3045620A1 (en) | 2018-06-21 |
US20180161853A1 (en) | 2018-06-14 |
CN110062673A (zh) | 2019-07-26 |
WO2018111408A1 (en) | 2018-06-21 |
EP3554748B1 (en) | 2022-06-15 |
CA3045620C (en) | 2022-06-28 |
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