US20050006047A1 - Investment casting method and cores and dies used therein - Google Patents

Investment casting method and cores and dies used therein Download PDF

Info

Publication number
US20050006047A1
US20050006047A1 US10/617,552 US61755203A US2005006047A1 US 20050006047 A1 US20050006047 A1 US 20050006047A1 US 61755203 A US61755203 A US 61755203A US 2005006047 A1 US2005006047 A1 US 2005006047A1
Authority
US
United States
Prior art keywords
die
ceramic
slurry
component
cavity
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.)
Abandoned
Application number
US10/617,552
Other languages
English (en)
Inventor
Hsin-Pang Wang
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.)
General Electric Co
Original Assignee
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by General Electric Co filed Critical General Electric Co
Priority to US10/617,552 priority Critical patent/US20050006047A1/en
Assigned to GENERAL ELECTRIC COMPANY reassignment GENERAL ELECTRIC COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: LEE, CHING-PANG, WANG, HSIN-PANG
Priority to AT04254053T priority patent/ATE361800T1/de
Priority to DE602004006342T priority patent/DE602004006342T2/de
Priority to EP04254053A priority patent/EP1495820B1/de
Priority to JP2004202670A priority patent/JP2005028455A/ja
Publication of US20050006047A1 publication Critical patent/US20050006047A1/en
Priority to US11/130,443 priority patent/US7413001B2/en
Abandoned legal-status Critical Current

Links

Images

Classifications

    • 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
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • This invention relates to investment casting of complex articles. More particularly, this invention relates to the manufacture and use of integral, sacrificial cores for investment casting complex articles.
  • a gas turbine engine compressed air is mixed with fuel in a combustor and ignited, generating a flow of hot combustion gases through one or more turbine stages that extract energy from the gas, producing output power.
  • Each turbine stage includes a stator nozzle having vanes that direct the combustion gases against a corresponding row of turbine blades extending radially outwardly from a supporting rotor disk.
  • the vanes and blades include airfoils having a generally concave “pressure” side and a generally convex “suction” side, both sides extending axially between leading and trailing edges over which the combustion gases flow during operation.
  • the vanes and blades are subject to substantial heat load, and, because the efficiency of a gas turbine engine is a function of gas temperature, the continuous demand for efficiency translates to a demand for airfoils that are capable of withstanding higher temperatures for longer service times.
  • Gas turbine airfoils on such components as vanes and blades are usually made of superalloys and are often cooled by means of internal cooling chambers.
  • the internal air-cooling of turbine airfoils is often accomplished via a complex cooling scheme in which cooling air flows through channels within the airfoil (“internal air-cooling channels”) and is then discharged through a configuration of cooling holes at the airfoil surface. Convection cooling occurs within the airfoil from heat transfer to the cooling air as it flows through the cooling channels.
  • Turbine components such as blades and vanes are often fabricated by investment casting, a technique used to manufacture complex, high-precision parts.
  • Investment casting is performed by first forming a wax pattern of the part to be cast, then encapsulating the wax pattern with a ceramic shell. The encapsulated shell is then heated to cure the ceramic and melt the wax, leaving a ceramic mold having a cavity in the precise shape of the part to be cast. Molten metal is then poured into the ceramic shell and solidified, and the ceramic is removed by a combination of mechanical and chemical means to produce a final metal casting suitable for various finishing operations.
  • Using this method to produce parts with internal channels is complicated by the need for the ceramic shell to include internal mold cores that define the channels.
  • an alternative method for forming casting cores that allows the formation of an integral core would be advantageous, especially in the fabrication of components having multiple walls. Furthermore, alternative methods for forming articles having multiple walls, where the method is less time-consuming and repeatable than current methods, would also be advantageous.
  • One embodiment is a method for making a component.
  • the method comprises providing a single-piece sacrificial die, the die comprising at least one internal cavity; introducing a ceramic slurry into the at least one cavity of the die, the slurry comprising a ceramic and a carrier fluid; curing the slurry to form a ceramic casting core; removing the sacrificial die by exposing the die to an environment adapted to destroy the die while leaving the ceramic casting core intact; and performing an investment casting process using the ceramic casting core as part of a mold-core assembly to form the component.
  • a second embodiment is a method for making a casting core.
  • the method comprises manufacturing a single-piece sacrificial die using an additive layer manufacturing method, the die comprising an internal cavity; introducing a ceramic slurry into the cavity of the die, the slurry comprising a ceramic and a carrier fluid; curing the slurry to form a ceramic casting core; and removing the sacrificial die by exposing the die to an environment adapted to destroy the die while leaving the ceramic casting core intact.
  • Embodiments of the present invention further include the casting core made by the above method.
  • a further embodiment is a die for making a casting core.
  • the die comprises a single-piece structure comprising at least one cavity, and this structure comprises a material capable of being selectively removed from a ceramic casting core when the ceramic casting core is disposed in the at least one cavity.
  • FIG. 1 is a cross sectional view of an exemplary component which is capable of being manufactured by embodiments of the present invention.
  • a component 10 is made according to method embodiments of the present invention.
  • component 10 comprises an external wall 20 and at least one internal wall 30 disposed in a spaced-apart relationship with external wall 20 .
  • Such components are referred to herein as “multi-wall components.”
  • a single-piece sacrificial die is provided.
  • Conventional dies are generally constructed to be used multiple times and are usually two-piece designs, but the complicated geometry of the cooling circuits used in multi-wall components 10 makes the use of dies having two pieces very difficult and often impossible, requiring in conventional methods additional time and effort for multiple injected cores to be formed and assembled into a composite core.
  • the single-piece sacrificial die comprises at least one internal cavity.
  • the singular term “cavity” will be used to refer to the at least one cavity within the die, but it should be understood that the use of the singular term “cavity” also refers to the case where more than one cavity is contained within the die.
  • the shape of the cavity corresponds to the shape desired for the complex mold core to be used in casting the component 10 .
  • the single-piece sacrificial die is provided through the use of one or more additive layer manufacturing processes.
  • the die in particular embodiments, comprises at least one sacrificial material selected from the group consisting of an epoxy, a silicone, and a metal.
  • a product is “assembled” by producing and sequentially stacking thin cross-sectional layers one on top of the other, generally starting at one end of the product and working towards the opposite end.
  • Such methods often use a three-dimensional computer-aided drafting (“CAD”) file of the product to guide an automated assembly process, where the CAD model file is digitally partitioned into “slices” corresponding to the actual layers being generated and stacked, and these “slices” guide automated assembling equipment such as, for example, robotic arms.
  • CAD computer-aided drafting
  • the nature of the additive layer process allows single-piece articles of high internal complexity, such as, for example, closed internal chambers and tortuous internal channels, to be easily assembled in one continuous operation. Therefore, additive layer manufacturing processes are well suited to the creation of a complicated single-piece die as used in embodiments of the present invention, because such a die will often be designed to have a complicated internal structure that corresponds to the complex internal cooling circuits of the component desired to be cast.
  • Stereolithography is an example of an additive layer process that is suitable for use in embodiments of the present invention.
  • a robotic arm holds a laser, and the arm precisely guides the motion of the laser along a motion path described by the “sliced” CAD file.
  • the laser directs highly focused radiation upon a curable material medium, often a liquid resin, which is instantly solidified (“cured”) upon exposure to the laser, thereby creating a single, precisely rendered cross-sectional layer of the product that corresponds with the “slice” of the partitioned CAD file. This procedure is repeated for all subsequent layers, with each layer being bonded to the previous one by the action of the solidifying material medium.
  • the finished product is a three-dimensional product rendered in cured material with all dimensions in accordance with the CAD file.
  • a long list of other additive layer manufacturing processes are available in the art and are suitable for providing the single-piece sacrificial die in embodiments of the present invention, including, but not limited to, micro-pen deposition, where liquid media is dispensed with high precision at the pen tip and then cured; selective laser sintering, where a laser is used to sinter a powder media in precisely controlled locations; and laser wire deposition, where a wire feedstock is melted by a laser and then deposited and solidified in precise locations to build the product.
  • curable material media may be applied, including liquid resins, as described above, and solid media in various forms such as powders, wires, and sheets. Silicone-based and organic-based resins are the most common examples of curable material media used in these methods, although in some methods the media comprises at least one metal, often mixed with some type of resin.
  • a ceramic slurry is introduced into the cavity (or cavities) of the sacrificial die.
  • the slurry comprises a ceramic powder and a liquid phase, or “carrier fluid.”
  • the slurry contains sufficient liquid phase to provide a viscosity that is usually less than about 10,000 Pascal-seconds, that is, a viscosity that renders the slurry suitable for introduction into, and proper filling of, the die cavity.
  • Suitable ceramics for use in the slurry include, but are not limited to, alumina, yttria, ceria, zirconia, magnesia, and calcia.
  • the introduction of the ceramic slurry into the cavity of the die is done with the slurry under pressure to ensure the slurry completely fills the cavity.
  • Injection molding is an example of a suitable method for introducing the slurry into the die cavity, because the quantity and pressure of the slurry may be precisely controlled as the slurry fills the die cavity.
  • the slurry is cured to form a ceramic casting core. Curing the slurry is done by removing the liquid phase, and in certain embodiments this is done by heating the slurry to evaporate the carrier fluid, leaving only the ceramic phase contained within the die cavity.
  • the die is then removed from around the ceramic casting core contained in the die cavity. Because the die is one piece, it cannot be removed without being destroyed, hence the die is sacrificial in the method of the present invention.
  • the die is exposed to an environment, such as, for example, mechanical stress, temperature, chemicals, and combinations thereof, that is adapted to destroy the die while leaving the ceramic casting core intact.
  • removing the die comprises heating the die.
  • the die is heated to a temperature that causes the die to decompose or burn away, while the ceramic core remains unaffected.
  • the die is removed by dissolving it in a solvent. Those skilled in the art will appreciate that the choice of solvent depends upon the composition of the die.
  • the die is chemically removed, such as, for example, by reacting the die material with an acid, base, or other compound or mixture that chemically reacts with and removes the die material. Regardless of how the die is removed, the environment is chosen to selectively remove the die material while leaving the ceramic material intact.
  • the ceramic core may be of a much higher complexity than is possible to achieve in a one-piece core made by conventional techniques, due to the use of the single-piece sacrificial die and, in certain embodiments, the use of the additive layer manufacturing process in making the die.
  • the core is often fired at a temperature in the range from about 870° C. to about 1100° C. to provide the core with sufficient strength to survive subsequent operations.
  • An investment casting process is performed in accordance with industry practice, using the ceramic core made above as part of a mold-core assembly to form component 10 .
  • the core and appropriate ancillary material known to those skilled in the art are disposed in a mold appropriately shaped in accordance with the design of the component to be cast. Wax is injected into the mold and solidified to form a wax model, and this wax model with embedded core is repeatedly dipped in ceramic slurry to form a ceramic shell mold around the wax pattern. After removing the wax, all that remains is the ceramic core disposed in and attached to the ceramic shell mold, thereby forming the mold-core assembly referred to above. After casting the component by solidifying molten metal in the mold-core assembly, the ceramic mold is removed by chemical or mechanical means and the core is “leached” out of the component by a chemical removal agent.
  • ancillary material such as positioning and support pins, sprues, gates, etc.
  • the use of the single-piece sacrificial die to make a one-piece ceramic core allows for repeatable production of high quality castings without the time-consuming steps of forming multiple core components and joining them together into a composite core prior to wax injection.
  • the component 10 being made is a component of a turbine assembly, such as, for example, a turbine blade or a vane, including multi-wall blades or vanes.
  • component 10 comprises at least one internal air-cooling passage 40 . Because the complexity of internal passage geometry is easily accommodated by the additive layer manufacturing process used to fashion the core die, adding additional features to the component is readily accomplished with little added expense.
  • the at least one cooling passage 40 of component 10 comprises turbulators (not shown) to enhance heat transfer within cooling passage 40 .
  • one embodiment of the present invention is a method for making a component for a turbine assembly.
  • the component is a multi-wall component, and therefore it comprises an external wall and at least one internal wall disposed in a spaced-apart relationship with the external wall, and further comprises at least one cooling passage disposed between the external wall and the internal wall.
  • the method comprises using a stereolithography process to provide a single-piece sacrificial die having at least one internal cavity; introducing a ceramic slurry as described previously into the at least one cavity of the die; curing the slurry to form a ceramic casting core; removing the sacrificial die by exposing the die to an environment adapted to destroy the die while leaving the ceramic casting core intact; and performing an investment casting process using the ceramic casting core as part of a mold-core assembly to form the component.
  • inventions of the present invention include a method for making a casting core, and the casting core made by the method.
  • a single-piece sacrificial die is manufactured using an additive layer manufacturing method as described above.
  • the die comprises at least one internal cavity, into which a ceramic slurry is introduced and then cured. After curing, the die is removed as previously described.
  • the various alternatives for materials and processes described for previous embodiments are equally applicable in this embodiment.
  • the core is configured to form internal passages, such as, for example, air-cooling passages, in an investment cast article. That is, the core is designed to correspond with the geometry of these passages, so that when the investment casting process is carried out, the ceramic core will be leached away from the internal surfaces of the component, leaving behind the desired configuration of internal passages.
  • the investment cast article for which the core is configured is a component of a turbine assembly, such as, for instance, a multi-wall component.
  • a further embodiment of the present invention is a die for making a casting core.
  • the die comprises a single piece structure having at least one cavity, and is made of a material capable of being selectively removed from a ceramic casting core when such a core is disposed in the cavity of the die. That is, the die material can be destroyed by an environment while a ceramic casting core disposed within the cavity of the die remains intact, as described previously.
  • the structure of the die comprises a structure assembled in an additive layer manufacturing process, such as the SLA process described previously.
US10/617,552 2003-07-10 2003-07-10 Investment casting method and cores and dies used therein Abandoned US20050006047A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
US10/617,552 US20050006047A1 (en) 2003-07-10 2003-07-10 Investment casting method and cores and dies used therein
AT04254053T ATE361800T1 (de) 2003-07-10 2004-07-07 Verfahren zur präzisionsgiessen
DE602004006342T DE602004006342T2 (de) 2003-07-10 2004-07-07 Verfahren zum Präzisionsgiessen
EP04254053A EP1495820B1 (de) 2003-07-10 2004-07-07 Verfahren zur Präzisionsgiessen
JP2004202670A JP2005028455A (ja) 2003-07-10 2004-07-09 インベストメント鋳造法並びにそれに用いるコア及びダイ
US11/130,443 US7413001B2 (en) 2003-07-10 2005-05-16 Synthetic model casting

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/617,552 US20050006047A1 (en) 2003-07-10 2003-07-10 Investment casting method and cores and dies used therein

Related Child Applications (2)

Application Number Title Priority Date Filing Date
US88514204A Continuation-In-Part 2003-07-10 2004-07-06
US11/130,443 Continuation-In-Part US7413001B2 (en) 2003-07-10 2005-05-16 Synthetic model casting

Publications (1)

Publication Number Publication Date
US20050006047A1 true US20050006047A1 (en) 2005-01-13

Family

ID=33452696

Family Applications (2)

Application Number Title Priority Date Filing Date
US10/617,552 Abandoned US20050006047A1 (en) 2003-07-10 2003-07-10 Investment casting method and cores and dies used therein
US11/130,443 Active 2024-07-26 US7413001B2 (en) 2003-07-10 2005-05-16 Synthetic model casting

Family Applications After (1)

Application Number Title Priority Date Filing Date
US11/130,443 Active 2024-07-26 US7413001B2 (en) 2003-07-10 2005-05-16 Synthetic model casting

Country Status (5)

Country Link
US (2) US20050006047A1 (de)
EP (1) EP1495820B1 (de)
JP (1) JP2005028455A (de)
AT (1) ATE361800T1 (de)
DE (1) DE602004006342T2 (de)

Cited By (36)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7302989B1 (en) 2006-06-06 2007-12-04 Siemens Power Generation, Inc. Modular mold system with ceramic inserts
US20080135721A1 (en) * 2006-12-06 2008-06-12 General Electric Company Casting compositions for manufacturing metal casting and methods of manufacturing thereof
US20080135718A1 (en) * 2006-12-06 2008-06-12 General Electric Company Disposable insert, and use thereof in a method for manufacturing an airfoil
US20080135202A1 (en) * 2006-12-06 2008-06-12 General Electric Company Composite core die, methods of manufacture thereof and articles manufactured therefrom
US20080135722A1 (en) * 2006-12-11 2008-06-12 General Electric Company Disposable thin wall core die, methods of manufacture thereof and articles manufactured therefrom
CN100444988C (zh) * 2005-11-02 2008-12-24 沈阳铸造研究所 一种制备整体制芯模具的方法
US20090160092A1 (en) * 2007-12-20 2009-06-25 David Brian Jahnz Precision casting process
US20100025001A1 (en) * 2007-06-25 2010-02-04 Ching-Pang Lee Methods for fabricating gas turbine components using an integrated disposable core and shell die
US7938168B2 (en) 2006-12-06 2011-05-10 General Electric Company Ceramic cores, methods of manufacture thereof and articles manufactured from the same
US20110156304A1 (en) * 2009-12-31 2011-06-30 Bryant Walker Die Tool Production Methods Utilizing Additive Manufacturing Techniques
US8884182B2 (en) 2006-12-11 2014-11-11 General Electric Company Method of modifying the end wall contour in a turbine using laser consolidation and the turbines derived therefrom
WO2015050987A1 (en) * 2013-10-04 2015-04-09 United Technologies Corporation Additive manufactured fuel nozzle core for a gas turbine engine
US9243502B2 (en) 2012-04-24 2016-01-26 United Technologies Corporation Airfoil cooling enhancement and method of making the same
US9296039B2 (en) 2012-04-24 2016-03-29 United Technologies Corporation Gas turbine engine airfoil impingement cooling
US20160326884A1 (en) * 2015-05-08 2016-11-10 United Technologies Corporation Axial skin core cooling passage for a turbine engine component
US9579714B1 (en) 2015-12-17 2017-02-28 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US9863254B2 (en) 2012-04-23 2018-01-09 General Electric Company Turbine airfoil with local wall thickness control
US9968991B2 (en) 2015-12-17 2018-05-15 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US9987677B2 (en) 2015-12-17 2018-06-05 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10046389B2 (en) 2015-12-17 2018-08-14 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10099283B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having an internal passage defined therein
US10099276B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having an internal passage defined therein
US10099284B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having a catalyzed internal passage defined therein
US10118217B2 (en) 2015-12-17 2018-11-06 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10137499B2 (en) 2015-12-17 2018-11-27 General Electric Company Method and assembly for forming components having an internal passage defined therein
US10150158B2 (en) 2015-12-17 2018-12-11 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10286450B2 (en) 2016-04-27 2019-05-14 General Electric Company Method and assembly for forming components using a jacketed core
US10335853B2 (en) 2016-04-27 2019-07-02 General Electric Company Method and assembly for forming components using a jacketed core
US20190314894A1 (en) * 2018-04-16 2019-10-17 Nick Pan System and method for rotational 3d printing
US20190338652A1 (en) * 2018-05-02 2019-11-07 United Technologies Corporation Airfoil having improved cooling scheme
US11143039B2 (en) 2015-05-08 2021-10-12 Raytheon Technologies Corporation Turbine engine component including an axially aligned skin core passage interrupted by a pedestal
US11230503B2 (en) 2017-06-27 2022-01-25 General Electric Company Resin for production of porous ceramic stereolithography and methods of its use
US11254031B2 (en) 2016-03-14 2022-02-22 Addifab Aps Additive manufacturing device and system for manufacturing a sacrificial mould for creating an object
US20220126365A1 (en) * 2018-08-20 2022-04-28 Honeywell International Inc. System and method for forming part from rapidly manufactured article
CN115041631A (zh) * 2022-05-30 2022-09-13 西安交通大学 一种空心涡轮叶片的多材料一体化铸型的制备方法及铸型
US11969918B2 (en) 2017-07-14 2024-04-30 Nexa3D Aps Sacrificial additively manufactured molds for use in injection molding processes

Families Citing this family (66)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10346953A1 (de) * 2003-10-09 2005-05-04 Mtu Aero Engines Gmbh Werkzeug zum Herstellen von Gussbauteilen, Verfahren zum Herstellen des Werkzeugs und Verfahren zum Herstellen von Gussbauteilen
EP1661640A1 (de) * 2004-11-24 2006-05-31 Siemens Aktiengesellschaft Verfahren zum Herstellen eines verlorenen Modells und darin eingebrachten Kern
GB0515550D0 (en) 2005-07-29 2005-09-07 Univ Strathclyde Inactivation of staphylococcus species
US8575513B2 (en) * 2006-07-06 2013-11-05 Siemens Energy, Inc. Rapid prototyping of ceramic articles
US8806871B2 (en) * 2008-04-11 2014-08-19 General Electric Company Fuel nozzle
US8177507B2 (en) * 2008-05-14 2012-05-15 United Technologies Corporation Triangular serpentine cooling channels
US8172533B2 (en) * 2008-05-14 2012-05-08 United Technologies Corporation Turbine blade internal cooling configuration
EP2559533B1 (de) 2008-09-26 2020-04-15 United Technologies Corporation Gussteil
EP2187005B1 (de) * 2008-11-14 2015-04-01 Siemens Aktiengesellschaft Verfahren zur Herstellung einer Turbinenschaufelhalterung für eine Durchflussmengenbestimmungseinrichtung
US9056795B2 (en) * 2009-08-09 2015-06-16 Rolls-Royce Corporation Support for a fired article
US8137604B2 (en) * 2009-08-26 2012-03-20 Toyota Motor Engineering & Manufacturing North America, Inc. Methods of creating soft formed hoses and molds
US8056606B2 (en) 2009-10-26 2011-11-15 General Electric Company Methods of making and using ceramic metallic interlocked components
US20110204205A1 (en) 2010-02-25 2011-08-25 Ahmed Kamel Casting core for turbine engine components and method of making the same
US10493689B1 (en) * 2010-09-02 2019-12-03 The Boeing Company Methods for forming thermoplastic parts with freeform tooling
US9587645B2 (en) * 2010-09-30 2017-03-07 Pratt & Whitney Canada Corp. Airfoil blade
US9492968B2 (en) 2011-01-28 2016-11-15 General Electric Company Three-dimensional powder molding
US20120274005A1 (en) * 2011-04-26 2012-11-01 General Electric Company Process for preparing for casting
US8915289B2 (en) 2011-05-10 2014-12-23 Howmet Corporation Ceramic core with composite insert for casting airfoils
US8899303B2 (en) 2011-05-10 2014-12-02 Howmet Corporation Ceramic core with composite insert for casting airfoils
US9925584B2 (en) 2011-09-29 2018-03-27 United Technologies Corporation Method and system for die casting a hybrid component
US8813824B2 (en) 2011-12-06 2014-08-26 Mikro Systems, Inc. Systems, devices, and/or methods for producing holes
US9193111B2 (en) 2012-07-02 2015-11-24 United Technologies Corporation Super polish masking of integrally bladed rotor
US20140003923A1 (en) 2012-07-02 2014-01-02 Peter Finnigan Functionally graded composite fan containment case
US10173932B1 (en) 2012-12-31 2019-01-08 General Electric Company Disposable core die and method of fabricating a ceramic body
US9835035B2 (en) 2013-03-12 2017-12-05 Howmet Corporation Cast-in cooling features especially for turbine airfoils
US9539764B2 (en) * 2013-03-15 2017-01-10 United Technologies Corporation Usage of a witness mark to distinguish support structure from part
US9415438B2 (en) 2013-04-19 2016-08-16 United Technologies Corporation Method for forming single crystal parts using additive manufacturing and remelt
EP3036055B1 (de) 2013-08-23 2019-07-03 Siemens Energy, Inc. Gusskern einer turbinenkomponente mit hoher auflösungsregion
US10174621B2 (en) 2013-10-07 2019-01-08 United Technologies Corporation Method of making an article with internal structure
BR112016011777A2 (pt) 2013-11-27 2017-08-08 Gen Electric Aparelhos de bocal de combustível
US10451282B2 (en) 2013-12-23 2019-10-22 General Electric Company Fuel nozzle structure for air assist injection
JP6695801B2 (ja) 2013-12-23 2020-05-20 ゼネラル・エレクトリック・カンパニイ 可撓性支持構造体を備えた燃料ノズル
DE102014203699A1 (de) * 2014-02-28 2015-09-03 Bayerische Motoren Werke Aktiengesellschaft Verfahren für die herstellung eines gusskerns für die fertigung von zylinderköpfen
US9463506B2 (en) 2014-04-15 2016-10-11 United Technologies Corporation Working additively manufactured parts
US9435211B2 (en) 2014-05-09 2016-09-06 United Technologies Corporation Method for forming components using additive manufacturing and re-melt
US9718127B2 (en) 2014-05-09 2017-08-01 United Technologies Corporation Method for forming components using additive manufacturing and re-melt
US9452474B2 (en) * 2014-05-09 2016-09-27 United Technologies Corporation Method for forming a directionally solidified replacement body for a component using additive manufacturing
US20150328678A1 (en) 2014-05-19 2015-11-19 General Electric Company Methods and compositions for formation of ceramic articles
US20170232506A1 (en) * 2014-10-15 2017-08-17 Siemens Aktiengesellschaft Die cast system with ceramic casting mold for forming a component usable in a gas turbine engine
US20160214165A1 (en) 2015-01-26 2016-07-28 General Electric Company Porous ceramic materials for investment casting
JP6559495B2 (ja) * 2015-07-29 2019-08-14 株式会社キャステム ロストワックス法を用いた鋳造品の製造方法
ITUB20154905A1 (it) 2015-10-20 2017-04-20 Nuovo Pignone Tecnologie Srl Metodo di produzione di pale di turbina
US9950358B2 (en) 2015-11-19 2018-04-24 General Electric Company Compositions for cores used in investment casting
US10697305B2 (en) 2016-01-08 2020-06-30 General Electric Company Method for making hybrid ceramic/metal, ceramic/ceramic body by using 3D printing process
US10227879B2 (en) 2016-02-11 2019-03-12 General Electric Company Centrifugal compressor assembly for use in a turbine engine and method of assembly
US20180009032A1 (en) 2016-07-08 2018-01-11 General Electric Company Metal objects and methods for making metal objects using disposable molds
US10400608B2 (en) 2016-11-23 2019-09-03 General Electric Company Cooling structure for a turbine component
US11813669B2 (en) 2016-12-13 2023-11-14 General Electric Company Method for making an integrated core-shell structure
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
US20180161866A1 (en) 2016-12-13 2018-06-14 General Electric Company Multi-piece integrated core-shell structure for making cast component
FR3067700B1 (fr) 2017-06-18 2021-02-12 Sogeclair Sa Structure metallique a peau renforcee et procede de fabrication de piece metallique raidie
US10974312B2 (en) 2017-06-28 2021-04-13 General Electric Company Additively manufactured casting core-shell mold with integrated filter and ceramic shell
US11173542B2 (en) 2017-06-28 2021-11-16 General Electric Company Additively manufactured casting core-shell mold and ceramic shell with variable thermal properties
US10391670B2 (en) 2017-06-28 2019-08-27 General Electric Company Additively manufactured integrated casting core structure with ceramic shell
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
US10646959B2 (en) * 2017-08-18 2020-05-12 General Electric Company Additive manufactured components including sacrifical caps and methods of forming same
US10610922B2 (en) 2017-09-08 2020-04-07 General Electric Company Ceramic slurry compositions and methods of use thereof
CN108083777B (zh) * 2017-11-10 2021-05-11 山东工业陶瓷研究设计院有限公司 一种光固化3d打印用铝基陶瓷料浆及陶瓷型芯的制备方法
RU2699139C2 (ru) * 2018-01-11 2019-09-03 Федеральное государственное бюджетное образовательное учреждение высшего образования "Казанский национальный исследовательский технический университет им. А.Н. Туполева-КАИ" (КНИТУ-КАИ) Способ изготовления составной модели для литья
WO2020018815A1 (en) * 2018-07-18 2020-01-23 Poly6 Technologies, Inc. Articles and methods of manufacture
JP7021709B2 (ja) 2018-09-20 2022-02-17 小野薬品工業株式会社 Ｄｐアンタゴニスト
US11806894B2 (en) * 2018-12-21 2023-11-07 Chromalloy Gas Turbine Llc Method and apparatus for improving core manufacturing for gas turbine components
US11813665B2 (en) * 2020-09-14 2023-11-14 General Electric Company Methods for casting a component having a readily removable casting core
GB202105026D0 (en) * 2021-04-08 2021-05-26 Siemens Energy Global Gmbh & Co Kg Aerofoil and method
KR102549163B1 (ko) * 2021-08-13 2023-06-28 윤병관 왁스rp용 3d프린팅이 이용된 가스터빈용 블레이드 제작방법

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5824250A (en) * 1996-06-28 1998-10-20 Alliedsignal Inc. Gel cast molding with fugitive molds
US6331267B1 (en) * 1999-11-16 2001-12-18 General Electric Company Apparatus and method for molding a core for use in casting hollow parts
US6368525B1 (en) * 2000-02-07 2002-04-09 General Electric Company Method for removing volatile components from a ceramic article, and related processes
US6375880B1 (en) * 1997-09-30 2002-04-23 The Board Of Trustees Of The Leland Stanford Junior University Mold shape deposition manufacturing
US6571484B2 (en) * 2000-02-02 2003-06-03 Rolls-Royce Plc Conformance gauge
US6609043B1 (en) * 2000-04-25 2003-08-19 Northrop Grumman Corporation Method and system for constructing a structural foam part
US6626230B1 (en) * 1999-10-26 2003-09-30 Howmet Research Corporation Multi-wall core and process

Family Cites Families (33)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3263957A (en) * 1961-02-09 1966-08-02 Howe Sound Co Apparatus for the production of ceramic, cermet, and metal components
JPS5445314A (en) * 1977-09-16 1979-04-10 Kubota Ltd Method of making centerless ceramic core
GB2028928B (en) * 1978-08-17 1982-08-25 Ross Royce Ltd Aerofoil blade for a gas turbine engine
GB2096523B (en) * 1981-03-25 1986-04-09 Rolls Royce Method of making a blade aerofoil for a gas turbine
JPS60247515A (ja) 1984-05-23 1985-12-07 Oosakafu 光学的造形法
FR2567668B1 (fr) 1984-07-16 1987-10-16 Cilas Alcatel Dispositif pour realiser un modele de piece industrielle
US4575330A (en) * 1984-08-08 1986-03-11 Uvp, Inc. Apparatus for production of three-dimensional objects by stereolithography
JPS61114818A (ja) 1984-11-09 1986-06-02 Fujitsu Ltd 立体形状形成装置
JPS61222659A (ja) * 1985-03-28 1986-10-03 Mitsubishi Metal Corp ロスト・ワツクス鋳造法におけるロウ型の成形法
ES2063737T3 (es) 1986-06-03 1995-01-16 Cubital Ltd Aparato y metodo para modelizacion tridimensional.
JPH01157742A (ja) 1987-12-14 1989-06-21 Honda Motor Co Ltd 中空中子の製造方法
US4844144A (en) * 1988-08-08 1989-07-04 Desoto, Inc. Investment casting utilizing patterns produced by stereolithography
US5136515A (en) * 1989-11-07 1992-08-04 Richard Helinski Method and means for constructing three-dimensional articles by particle deposition
FR2654538B1 (fr) 1989-11-16 1993-08-27 Electricite De France Procede et dispositif pour realiser un modele de piece industrielle par polymerisation d'un liquide monomere.
US5740051A (en) * 1991-01-25 1998-04-14 Sanders Prototypes, Inc. 3-D model making
US5295530A (en) * 1992-02-18 1994-03-22 General Motors Corporation Single-cast, high-temperature, thin wall structures and methods of making the same
JPH084874B2 (ja) * 1992-05-01 1996-01-24 株式会社大阪シェル工業所 中空中子の製造方法
US5660524A (en) * 1992-07-13 1997-08-26 General Electric Company Airfoil blade having a serpentine cooling circuit and impingement cooling
JPH0747443A (ja) * 1993-08-06 1995-02-21 Yamagata Seimitsu Chuzo Kk ロストワックス鋳造方法
US5484258A (en) * 1994-03-01 1996-01-16 General Electric Company Turbine airfoil with convectively cooled double shell outer wall
JPH0952145A (ja) * 1995-08-14 1997-02-25 Ebara Kinzoku:Kk 精密鋳造法
JPH0966344A (ja) * 1995-08-31 1997-03-11 Olympus Optical Co Ltd 光造形樹脂をマスターとした金属鋳造品の鋳造方法
GB9601910D0 (en) * 1996-01-31 1996-04-03 Rolls Royce Plc A method of investment casting and a method of making an investment casting mould
US5820774A (en) * 1996-10-28 1998-10-13 United Technologies Corporation Ceramic core for casting a turbine blade
US6051179A (en) * 1997-03-19 2000-04-18 Replicator Systems, Inc. Apparatus and method for production of three-dimensional models by spatial light modulator
US6126396A (en) * 1998-12-09 2000-10-03 General Electric Company AFT flowing serpentine airfoil cooling circuit with side wall impingement cooling chambers
US6152211A (en) * 1998-12-31 2000-11-28 General Electric Company Core compositions and articles with improved performance for use in castings for gas turbine applications
US6174133B1 (en) * 1999-01-25 2001-01-16 General Electric Company Coolable airfoil
JP2000254759A (ja) * 1999-03-05 2000-09-19 Daido Steel Co Ltd 精密鋳造用鋳型の製造方法
US6257831B1 (en) * 1999-10-22 2001-07-10 Pratt & Whitney Canada Corp. Cast airfoil structure with openings which do not require plugging
US20020187065A1 (en) * 2001-06-06 2002-12-12 Amaya Herman Ernesto Method for the rapid fabrication of mold inserts
US20050156361A1 (en) * 2004-01-21 2005-07-21 United Technologies Corporation Methods for producing complex ceramic articles
US20050258577A1 (en) * 2004-05-20 2005-11-24 Holowczak John E Method of producing unitary multi-element ceramic casting cores and integral core/shell system

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5824250A (en) * 1996-06-28 1998-10-20 Alliedsignal Inc. Gel cast molding with fugitive molds
US6375880B1 (en) * 1997-09-30 2002-04-23 The Board Of Trustees Of The Leland Stanford Junior University Mold shape deposition manufacturing
US6626230B1 (en) * 1999-10-26 2003-09-30 Howmet Research Corporation Multi-wall core and process
US6331267B1 (en) * 1999-11-16 2001-12-18 General Electric Company Apparatus and method for molding a core for use in casting hollow parts
US6502801B2 (en) * 1999-11-16 2003-01-07 General Electric Company Apparatus and method for molding a core for use in casting hollow parts
US6571484B2 (en) * 2000-02-02 2003-06-03 Rolls-Royce Plc Conformance gauge
US6368525B1 (en) * 2000-02-07 2002-04-09 General Electric Company Method for removing volatile components from a ceramic article, and related processes
US6609043B1 (en) * 2000-04-25 2003-08-19 Northrop Grumman Corporation Method and system for constructing a structural foam part

Cited By (48)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100444988C (zh) * 2005-11-02 2008-12-24 沈阳铸造研究所 一种制备整体制芯模具的方法
US20070277954A1 (en) * 2006-06-06 2007-12-06 Siemens Power Generation, Inc. Modular mold system with ceramic inserts
US7302989B1 (en) 2006-06-06 2007-12-04 Siemens Power Generation, Inc. Modular mold system with ceramic inserts
US20080135718A1 (en) * 2006-12-06 2008-06-12 General Electric Company Disposable insert, and use thereof in a method for manufacturing an airfoil
US20080135202A1 (en) * 2006-12-06 2008-06-12 General Electric Company Composite core die, methods of manufacture thereof and articles manufactured therefrom
US8413709B2 (en) 2006-12-06 2013-04-09 General Electric Company Composite core die, methods of manufacture thereof and articles manufactured therefrom
US9566642B2 (en) 2006-12-06 2017-02-14 General Electric Company Composite core die, methods of manufacture thereof and articles manufactured therefrom
US7624787B2 (en) 2006-12-06 2009-12-01 General Electric Company Disposable insert, and use thereof in a method for manufacturing an airfoil
US20080135721A1 (en) * 2006-12-06 2008-06-12 General Electric Company Casting compositions for manufacturing metal casting and methods of manufacturing thereof
US7938168B2 (en) 2006-12-06 2011-05-10 General Electric Company Ceramic cores, methods of manufacture thereof and articles manufactured from the same
US20080135722A1 (en) * 2006-12-11 2008-06-12 General Electric Company Disposable thin wall core die, methods of manufacture thereof and articles manufactured therefrom
US7487819B2 (en) 2006-12-11 2009-02-10 General Electric Company Disposable thin wall core die, methods of manufacture thereof and articles manufactured therefrom
US8884182B2 (en) 2006-12-11 2014-11-11 General Electric Company Method of modifying the end wall contour in a turbine using laser consolidation and the turbines derived therefrom
US20100025001A1 (en) * 2007-06-25 2010-02-04 Ching-Pang Lee Methods for fabricating gas turbine components using an integrated disposable core and shell die
US20090160092A1 (en) * 2007-12-20 2009-06-25 David Brian Jahnz Precision casting process
US20110156304A1 (en) * 2009-12-31 2011-06-30 Bryant Walker Die Tool Production Methods Utilizing Additive Manufacturing Techniques
US9863254B2 (en) 2012-04-23 2018-01-09 General Electric Company Turbine airfoil with local wall thickness control
US10500633B2 (en) 2012-04-24 2019-12-10 United Technologies Corporation Gas turbine engine airfoil impingement cooling
US9243502B2 (en) 2012-04-24 2016-01-26 United Technologies Corporation Airfoil cooling enhancement and method of making the same
US9296039B2 (en) 2012-04-24 2016-03-29 United Technologies Corporation Gas turbine engine airfoil impingement cooling
US9975169B2 (en) 2013-10-04 2018-05-22 United Technologies Corporation Additive manufactured fuel nozzle core for a gas turbine engine
WO2015050987A1 (en) * 2013-10-04 2015-04-09 United Technologies Corporation Additive manufactured fuel nozzle core for a gas turbine engine
US11143039B2 (en) 2015-05-08 2021-10-12 Raytheon Technologies Corporation Turbine engine component including an axially aligned skin core passage interrupted by a pedestal
US10323524B2 (en) * 2015-05-08 2019-06-18 United Technologies Corporation Axial skin core cooling passage for a turbine engine component
US20160326884A1 (en) * 2015-05-08 2016-11-10 United Technologies Corporation Axial skin core cooling passage for a turbine engine component
US10099284B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having a catalyzed internal passage defined therein
US10046389B2 (en) 2015-12-17 2018-08-14 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10099283B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having an internal passage defined therein
US10099276B2 (en) 2015-12-17 2018-10-16 General Electric Company Method and assembly for forming components having an internal passage defined therein
US9987677B2 (en) 2015-12-17 2018-06-05 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10118217B2 (en) 2015-12-17 2018-11-06 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US10137499B2 (en) 2015-12-17 2018-11-27 General Electric Company Method and assembly for forming components having an internal passage defined therein
US10150158B2 (en) 2015-12-17 2018-12-11 General Electric Company Method and assembly for forming components having internal passages using a jacketed core
US9579714B1 (en) 2015-12-17 2017-02-28 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US9975176B2 (en) 2015-12-17 2018-05-22 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US9968991B2 (en) 2015-12-17 2018-05-15 General Electric Company Method and assembly for forming components having internal passages using a lattice structure
US11254031B2 (en) 2016-03-14 2022-02-22 Addifab Aps Additive manufacturing device and system for manufacturing a sacrificial mould for creating an object
US10286450B2 (en) 2016-04-27 2019-05-14 General Electric Company Method and assembly for forming components using a jacketed core
US10981221B2 (en) 2016-04-27 2021-04-20 General Electric Company Method and assembly for forming components using a jacketed core
US10335853B2 (en) 2016-04-27 2019-07-02 General Electric Company Method and assembly for forming components using a jacketed core
US11230503B2 (en) 2017-06-27 2022-01-25 General Electric Company Resin for production of porous ceramic stereolithography and methods of its use
US11969918B2 (en) 2017-07-14 2024-04-30 Nexa3D Aps Sacrificial additively manufactured molds for use in injection molding processes
US20190314894A1 (en) * 2018-04-16 2019-10-17 Nick Pan System and method for rotational 3d printing
US11273496B2 (en) * 2018-04-16 2022-03-15 Panam 3D Llc System and method for rotational 3D printing
US20190338652A1 (en) * 2018-05-02 2019-11-07 United Technologies Corporation Airfoil having improved cooling scheme
US10753210B2 (en) * 2018-05-02 2020-08-25 Raytheon Technologies Corporation Airfoil having improved cooling scheme
US20220126365A1 (en) * 2018-08-20 2022-04-28 Honeywell International Inc. System and method for forming part from rapidly manufactured article
CN115041631A (zh) * 2022-05-30 2022-09-13 西安交通大学 一种空心涡轮叶片的多材料一体化铸型的制备方法及铸型

Also Published As

Publication number Publication date
EP1495820B1 (de) 2007-05-09
US20050205232A1 (en) 2005-09-22
US7413001B2 (en) 2008-08-19
EP1495820A1 (de) 2005-01-12
DE602004006342D1 (de) 2007-06-21
DE602004006342T2 (de) 2008-05-21
ATE361800T1 (de) 2007-06-15
JP2005028455A (ja) 2005-02-03

Similar Documents

Publication Publication Date Title
EP1495820B1 (de) Verfahren zur Präzisionsgiessen
EP1614488B2 (de) Giessverfahren mit Verwendung von durch Stereolithographie hergestellte Giesskerne
EP1634665B1 (de) Verbundkern zur Verwendung beim Feingiessen
JP4906210B2 (ja) 多層中子及びその製造方法
US20170246678A1 (en) Casting with first metal components and second metal components
CA2958128C (en) Casting with metal components and metal skin layers
EP3381585B1 (de) Vorrichtung und verfahren zur herstellung mehrwandiger kanäle in bauteilen
CN107127300A (zh) 利用递变芯部构件的铸造
US20220098119A1 (en) Resin for production of porous ceramic stereolithography and methods of its use
JP6929108B2 (ja) ジャケット付き中子を使用して部品を形成するための方法及びアセンブリ
CN102413969B (zh) 包括多个安装在平台中的叶片的组件的制造方法
CA3019799C (en) High temperature engineering stiffness core-shell mold for casting
JP2010110795A (ja) 一体型の使い捨て中子及びシェルダイを使用してガスタービン構成要素を製造する方法
EP3365130B1 (de) Verfahren zur herstellung einer turbinenschaufel
EP3210693B1 (de) Herstellungsverfahren eines bauteils mit einer zweiten metallkomponente, die um eine erste metallkomponente geformt ist, unter verwendung von isostatischem pressen
GB2465181A (en) Casting turbine components using a shell casting mould having an integral core
WO2024025597A1 (en) Multiwall ceramic core and method of making a multiwall ceramic core using a polymer fugitive
WO2024025596A1 (en) Multiwall ceramic core and method of making a multiwall ceramic core using a non-sinterable ceramic fugitive

Legal Events

Date Code Title Description
AS Assignment

Owner name: GENERAL ELECTRIC COMPANY, NEW YORK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:WANG, HSIN-PANG;LEE, CHING-PANG;REEL/FRAME:014291/0764;SIGNING DATES FROM 20030707 TO 20030708

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION