WO2024025597A1 - Noyau céramique à parois multiples et procédé de fabrication d'un noyau céramique à parois multiples à l'aide d'une matière fugitive polymère - Google Patents
Noyau céramique à parois multiples et procédé de fabrication d'un noyau céramique à parois multiples à l'aide d'une matière fugitive polymère Download PDFInfo
- Publication number
- WO2024025597A1 WO2024025597A1 PCT/US2022/074170 US2022074170W WO2024025597A1 WO 2024025597 A1 WO2024025597 A1 WO 2024025597A1 US 2022074170 W US2022074170 W US 2022074170W WO 2024025597 A1 WO2024025597 A1 WO 2024025597A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- multiwall
- ceramic
- ceramic core
- fugitive
- core
- Prior art date
Links
- 239000000919 ceramic Substances 0.000 title claims abstract description 136
- 229920000642 polymer Polymers 0.000 title claims abstract description 72
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 13
- 238000005245 sintering Methods 0.000 claims abstract description 18
- 238000002844 melting Methods 0.000 claims abstract description 4
- 230000008018 melting Effects 0.000 claims abstract description 4
- 239000002245 particle Substances 0.000 claims description 43
- 238000000034 method Methods 0.000 claims description 21
- 239000000203 mixture Substances 0.000 claims description 11
- 239000001993 wax Substances 0.000 claims description 10
- 238000001816 cooling Methods 0.000 claims description 9
- 238000000280 densification Methods 0.000 claims description 7
- 238000010248 power generation Methods 0.000 claims description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 5
- 238000012546 transfer Methods 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 4
- 238000002347 injection Methods 0.000 claims description 4
- 239000007924 injection Substances 0.000 claims description 4
- 239000007787 solid Substances 0.000 claims description 4
- 229920001778 nylon Polymers 0.000 claims description 3
- 229920000747 poly(lactic acid) Polymers 0.000 claims description 3
- 239000004626 polylactic acid Substances 0.000 claims description 3
- 229920001187 thermosetting polymer Polymers 0.000 claims description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 2
- 239000011889 copper foil Substances 0.000 claims description 2
- 238000009760 electrical discharge machining Methods 0.000 claims description 2
- 239000011888 foil Substances 0.000 claims description 2
- 239000000377 silicon dioxide Substances 0.000 claims description 2
- 229910052845 zircon Inorganic materials 0.000 claims description 2
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 2
- 238000005266 casting Methods 0.000 description 11
- 239000000463 material Substances 0.000 description 7
- 230000000712 assembly Effects 0.000 description 6
- 238000000429 assembly Methods 0.000 description 6
- 238000013461 design Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 230000005611 electricity Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 238000001746 injection moulding Methods 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000002441 reversible effect Effects 0.000 description 2
- KJLPSBMDOIVXSN-UHFFFAOYSA-N 4-[4-[2-[4-(3,4-dicarboxyphenoxy)phenyl]propan-2-yl]phenoxy]phthalic acid Chemical compound C=1C=C(OC=2C=C(C(C(O)=O)=CC=2)C(O)=O)C=CC=1C(C)(C)C(C=C1)=CC=C1OC1=CC=C(C(O)=O)C(C(O)=O)=C1 KJLPSBMDOIVXSN-UHFFFAOYSA-N 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000005094 computer simulation Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- -1 ethyl silicates Chemical class 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- 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
- B22C7/00—Patterns; Manufacture thereof so far as not provided for in other classes
- B22C7/06—Core boxes
-
- 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
Definitions
- the present invention relates to a multiwall ceramic core and more specifically to a multiwall ceramic core with a polymer fugitive designed and constructed for use in the manufacture of a multiwall gas turbine airfoil adapted for the power generation industry.
- gas turbine engines are required to provide movement to produce electricity in a generator or to produce thrust.
- compressed air discharged from a compressor section and fuel introduced from a source of fuel are mixed together and burned in a combustion section, creating combustion products defining a high temperature working gas.
- the working gas is directed through a hot gas path in a turbine section of the engine, where the working gas expands to provide rotation of a turbine rotor.
- the turbine rotor may be linked to an electric generator, wherein the rotation of the turbine rotor can be used to produce electricity in the generator, or to an exhaust to generate thrust.
- Effective cooling of the turbine airfoils requires delivering the relatively cool air to critical regions of the turbine airfoils, such as along internal passageways and the leading or trailing edge.
- airfoils may include internal cooling channels which remove heat from the pressure sidewall and the suction sidewall in order to minimize thermal stresses.
- associated cooling apertures may extend between an upstream, relatively high pressure cavity within the airfoil and one of the exterior surfaces of the turbine blade.
- One aspect or configuration involves a multiwall ceramic core comprising a main body portion comprising a ceramic having a sintering temperature; and a polymer fugitive arranged within and encapsulated by the main body portion, the polymer fugitive having a melting temperature below the sintering temperature of the ceramic but above a temperature required to partially sinter and densify the ceramic, and the polymer fugitive occupying a volume defining an internal geometry portion of the multiwall ceramic core.
- Another aspect or configuration involves a method of manufacturing a multiwall ceramic core using a polymer fugitive comprising forming a mold from a master tooling assembly; introducing the polymer fugitive into the mold; surrounding the polymer fugitive with ceramic particles introduced into the mold to form a green body; heating the green body to a temperature that is (i) sufficiently low so as to not fully sinter the ceramic particles while partially sintering the ceramic particles in order to provide intermediate strength to the green body via ceramic particle partial densification and (ii) sufficient high to melt or burn off the polymer fugitive; and sintering the green body to a temperature sufficiently high to sinter the ceramic particles, wherein the sintered ceramic particles form a main body portion of the ceramic core and wherein the melted or burned off polymer fugitive creates a volume within the main body defining an internal geometry of the multiwall ceramic core.
- FIG 1 is a logic flowchart illustrating steps to manufacture a multiwall ceramic core using a polymer fugitive in accordance with an aspect of the subject matter
- FIG 2 is a perspective view of a portion of a hard master tooling assembly in accordance with an aspect of the subject matter
- FIG 3 is a perspective view of a portion of a flexible master tooling assembly in accordance with an aspect of the subject matter
- FIG 4 is a side view of a portion of the flexible master tooling assembly of Figure 3;
- FIG 5 is a side view of a polymer fugitive arranged within a mold made from the master tooling assembly
- FIG 6 is a side view of ceramic particles arranged within the mold and surrounding the polymer fugitive to thereby form a green body multiwall ceramic core;
- FIG 7 is a perspective view of an exemplary embodiment of a finished green body multi wall ceramic core of the subject matter castable into a multiwall airfoil of the subject matter;
- FIG 8 is a perspective view of another exemplary embodiment of a finished green body and multiwall ceramic core castable into a multiwall airfoil of the subject matter;
- any reference to airfoils, gas turbines and the power industry may also be for other products, processes and industries that may require a core made from a casting or other manufacturing process.
- a turbine airfoil is used below as a contextual example of utilization of various master tooling assemblies and various ceramic cores from which a multiwall component may be made; however, the master tooling assemblies and ceramic cores may be used for any component requiring cast multiwall features.
- the exemplary multiwall gas turbine airfoil can be within the power generation industry.
- the core is often described in context of a ceramic material for casting purposes, the core may also be of any other material or purposes that functions in a similar fashion.
- a multiwall ceramic core 10 and a method of making a multiwall ceramic core 10 using a polymer fugitive 6 is provided.
- the multiwall ceramic core 10 is designed and constructed for use in the manufacture of a multiwall gas turbine airfoil 12 and adapted for use in the power generation industry.
- the method of making a multi wall ceramic core 10 involves utilization of a master tooling assembly 2 (Fig 2) which may optionally include a flexible liner 40 (Figs 3 and 4) to generate a mold 4 in the desired form of the ceramic core 10.
- a polymer fugitive 6 is then introduced into the mold 4 (Fig 5) followed by introduction of ceramic particles 8 into the mold 4 arranged to encapsulate the polymer fugitive 6 (Fig 6) in order to form a green body 54 of the multiwall ceramic core 10.
- the green body 54 can then be treated e.g. heated (e.g. for polymer fugitive 6 and carrier 62 removal, as well as for intermediate strengthening of the green body 54 via ceramic particle 8 partial densification), sintered (e.g. for ceramic particle 8 sintering and densification) and otherwise post-sinter processed (e.g.
- the sintered ceramic particles 8 occupy a space or volume defining a main body 64 portion of the multiwall ceramic core 10 and the removed polymer fugitive 6 creates a space or volume defining an internal geometry 66 portion of the multiwall ceramic core 10 (Figs 7 and 8).
- the finished multiwall ceramic core 10 can then be cast to create a multiwall gas turbine airfoil 12.
- a master tooling assembly 2 may be made and utilized in any of several ways, each of which having its own advantages and disadvantages.
- a hard master tooling 14 may be used, or a flexible master tooling 16 may be used; both are described below.
- aspects of one or more of the master tooling assemblies 2 may be combined or mixed and matched, as appropriate, such as using a flexible liner 40 of the flexible master tooling 16 with a hard master tooling 14.
- one system to produce a master tooling assembly 2 for ceramic cores 10 includes a hard master tooling 14 that can be made via multi axis precision machining (typically from computer numerical control machines i.e. CNC) of a hard aluminum block to define the positive surface geometry of one side of a tooling block 18. Since intricate non-conformal master tooling features are quite difficult to machine, in areas where non-conformal features are required, an insert 20 can be applied to define the tooling block 18 surface geometry.
- the insert 20 is typically made from either photo foil, chemically etched copper foil, or other suitable material.
- the insert 20 is then bonded onto the tooling block 18 to form a three dimensional surface or electrical discharge machining (EDM) machined insert of the hard master tooling 14.
- EDM electrical discharge machining
- FIG. 3 and 4 another way to produce a master tooling assembly 2 for ceramic cores 10 that allows for advanced and fine features and well as for rapid low cost master tooling assemblies 2 and multiple variants in the master tooling assembly 2 can start with a 3D computer model of a desired airfoil 12 to be created.
- the flexible master tooling 16 may be produced with a backing plate 22 and a plurality of lithographically derived inserts 24. With this flexible master tooling 16, there is no need for precision machined surfaces produced from CNC machines, which are replaced with the plurality of lithographically derived inserts 24 and backing plate 22 to form a flexible liner 40.
- the backing plate 22 may serve as a locator surface for the plurality of lithographically derived inserts 24 pieced together to define a tooling surface 32.
- Such features may include, but are not limited to, simple mechanical interlocking features and/or alignment locating features. Additionally, inserts may also be bonded with reversible bonding compounds.
- the backing plate 22 may be a single step machined surface.
- the backing plate 22 may include a top surface 30, side surfaces 28, and a bottom surface 26.
- the plurality of lithographically derived inserts 24 may be produced by stereolithographic apparatus which converts liquid plastic into solid objects. Such technology may be used to create surface features not producible by traditional machining methods. Such technology may also be used to produce accurate surface tolerances as required for high definition applications.
- Each of the plurality of lithographically derived inserts 24 may include a bottom surface 34, side surfaces 36, and a positive top surface 38, that may become the tooling surface 32.
- the positive top surface 38 may be non-conformal.
- the plurality of lithographically derived inserts 24 may expand across the entire top surface 30 of the backing plate 22.
- the plurality of lithographically derived inserts 24 may include various amounts of pieces.
- the plurality of lithographically derived inserts 24 includes three through eight inserts. The amount of plurality of lithographically derived inserts 24 may depend upon the complexity of the surface geometry and the degree of flexibility requested.
- a method of manufacturing the flexible master tooling 16 may include providing the plurality of lithographically derived inserts 24.
- the backing plate 22 may be provided as a locating surface for the plurality of lithographically derived inserts 24.
- the plurality of lithographically derived inserts 24 may be pieced together and placed on the backing plate 22 to form a flexible liner 40.
- a non-conformal positive surface is generated from the plurality of lithographically derived inserts 24 pieced together. Examples of piecing together or combining a plurality of lithographically derived inserts 24 may involve, but is not limited to, 1) interlocking into the backing plate 22, 2) precision thin layer bonding, and 3) vacuum assisted surface contacting.
- the precision thin layer bonding may be with accomplished with a reversible thin layer bonding media.
- the backing plate 22 may include suction ports located in the top surface 30 of the backing plate 22.
- the first plurality of lithographically derived inserts 24 and the backing plate 22 may form a first half 42 of a flexible liner 40 of the flexible master tooling 16.
- a second half 44 of the flexible master tooling 16 may be formed by a second plurality of lithographically derived inserts 46 and a second backing plate 48 to form a second portion of the flexible liner 40.
- the second backing plate 48 may include a top surface 30, side surfaces 28, and a bottom surface 26.
- the second half 44 of the flexible master tooling 16 may be combined with the first half 42 of the flexible master tooling 16 to form a mold 4 cavity. The combining of the first half 42 and the second half 44 of the flexible master tooling 16 provides the assembled flexible master tooling 16 with flexible liner 40.
- Two negative flexible transfer molds may be created from the non-conformal positive surfaces of the plurality of lithographically derived inserts 24 and a second plurality of lithographically derived inserts 46 respectively.
- the negative flexible transfer molds may then be combined to produce a mold 4 having a flexible liner 40.
- the illustrated second plurality of lithographically derived inserts 46 and the second backing plate 48 advantageously have the same or similar properties as the first plurality of lithographically derived inserts 24 and the backing plate 22 except for the second plurality of lithographically derived inserts 46 may have different non-conformal positive surfaces.
- Each of the second plurality of lithographically derived inserts 46 may include a bottom surface 34, side surfaces 36, and a positive top surface 38, that may become the tooling surface 26.
- the backing plate 22 may be a single step machined surface.
- Each of the first plurality of lithographically derived inserts 24 and second plurality of lithographically derived inserts 46 may be interchanged for other lithographically derived inserts 24, 46 for minor changes.
- this method with interchangeable first plurality of lithographically derived inserts 24 and second plurality of lithographically derived inserts 46 allows for quick adjustments.
- the flexible master tooling 16, being readily adjustable, allows for a reduction in manufacturing costs and reduces the time in between required changes.
- the third logic box discloses a polymer fugitive 6.
- the polymer fugitive 6 is introduced into the mold 4 made from the master tooling assembly 2 such that the polymer fugitive 6 occupies a space or geometric volume that will define an internal geometry 66 portion of the multiwall ceramic core 10, as discussed in more detail below.
- the polymer fugitive 6 may be made from any of a variety of materials that melt at temperatures below the processing temperature of the ceramic core 4. Suitable materials include but are not limited to poly lactic acid, as well as photo sensitive polymers, high temperature waxes, thermoset or optically cured polymers (printed or injected), nylons, and non-solid architectural (engineered porosity) fugitives.
- the polymer fugitive 6 can be injection molded or printed in various levels of density ranging from 30-100% dense.
- the polymer fugitive 6 is advantageously configured to melt or burn off at a temperature of 400 to 1400 degrees F, preferably 600 to 1100 degrees F and most preferably 750-900 degrees F, which is below the sintering processing temperature of the ceramic core 4.
- the polymer fugitive 6 has appreciable dimensional stability as a particulate to occupy a space or volume to define an internal geometry 66 portion of the multiwall ceramic core 10.
- the polymer fugitive 6 then may be introduced into the mold 4 by placing, adhering, pumping, injecting or otherwise arranging the non-sinterable ceramic fugitive 6 into the mold 4.
- the specific location, size and geometry of the polymer fugitive 6 within the mold 4 is typically an important core 10 and airfoil 12 design consideration.
- at least a first portion 56 of the internal geometry 66 occupied by the polymer fugitive 6 extends contiguously along at least 25% of a length of the core 10, and depending on the particular application at least 50% of a length of the core 10, and in certain applications such as that shown in Figures 7 and 8, at least 75% of a length of the core 10.
- a first portion 56 of the internal geometry occupied by the polymer fugitive 6 extends contiguously along at least 25% of a first length of the core 10
- a second portion 58 of the internal geometry occupied by the polymer fugitive 6 extends contiguously along at least 25% of a second length of the core 10
- a third portion 60 of the internal geometry occupied by the polymer fugitive 6 connects the first portion 56 and the second portion 58; although the at least 25% length of the first and/or second portions 56, 68 may be increased to at least 50% or even at least 75% as noted in the prior example.
- the polymer fugitive 6 may occupy a volume of between 5% and 25% of the total volume of the core 10, but depending on the particular application and airfoil 12, the polymer fugitive 6 volume may instead be less than 5% or greater than 25%, with volumes of 2%-10% and 20%-50% and 60%-80% of the total volume of the core 10 suitable.
- the size, location and geometry occupied by the polymer fugitive 6 space can be matched to the size, location and geometry of some or all of the ceramic core 10 and airfoil 12 internal cooling holes or a portion of or all of the leading or trailing edge portion of the airfoil 12.
- the mold 4 is ready for receipt of the ceramic particles 8 which are advantageously arranged to surround or encapsulate the polymer fugitive 6.
- One way for the mold 4 to receive the ceramic particles 8 is to arrange the mold 4 onto a wax injection press and lock down the mold 4 thereon.
- the ceramic particles 8 then may be introduced in the mold 4 via any suitable means such as an injected pressurized wax/ceramic mixture discussed below
- the fourth logic box discloses ceramic particles 8.
- the ceramic particles 8 are introduced into the mold 4 made from the master tooling assembly 2 such that ceramic particles 8 surround or encapsulate the polymer fugitive 6 while also occupying a space or volume defining a main body 64 portion of the multiwall ceramic core 10, as discussed in more detail below.
- the ceramic particles 8 may be selected from any of a variety of ceramic material core mix compositions.
- Exemplary suitable ceramic particles 8 include compositions including one or more of silica, zircon, alumina and the like in order to provide for high temperature thermal stability and core teachability and also convert to a majority low volume phase (cristobalite) to allow for metal solidification without hot tear defects.
- a binder could be optionally used with the ceramic particles 8, if used, suitable binders include but are not limited to waxes, ethyl silicates, liquid polymer or water based systems
- a ceramic particle 8 material composition can be introduced into the mold 4 so as to surround or encapsulate the polymer fugitive 6, in any of a variety of techniques.
- the ceramic particles 8 can be placed within a carrier 62 such as liquid wax prepared to a desired consistency by any of a variety of mixing or combining techniques.
- the mixture of ceramic particles 8 and carrier 62 may be introduced into the mold 4 by, for example, high pressure wax injection molding.
- This process may utilize a hydraulic wax press capable of injecting the ceramic/carrier mixture 8, 62 at pressure of 200 to 900 psi range and temperatures between 110 to 200 degrees F into the mold 4 to thereby surround or encapsulate the polymer fugitive 6.
- the ceramic/carrier mixture 8, 62 may then be allowed to cool to between 110 to 80 degrees F prior to extraction from the mold 4.
- any of a variety of other suitable ceramic particle mold introduction techniques may be used including but are not limited to low pressure injection molding, vacuum injection, poured core under vibration etc.
- the introduced ceramic particles 8 form a main body 64 portion of the ceramic core 4.
- a green body 54 is thereby formed having a polymer fugitive 6 forming an internal geometry 66 portion of the ceramic core 10 within and encapsulated by ceramic particles 8 forming a main body 64 portion of the ceramic core 10.
- the green body 54 can then be further processed into a finished multiwall ceramic core 10, with the ceramic particles 8 forming a main body 64 portion of the multiwall ceramic core 10 and the polymer fugitive 6 occupying a space or volume defining an internal geometry 66 portion of the multiwall ceramic core 10.
- the green body 54 can then by treated e.g. heated to a temperature of 400 to 1400 degrees F in order to melt, burn off and otherwise remove polymer fugitive 6 and carrier 62, and to provide some intermediate strength to the green body 54 via ceramic particle 8 partial densification.
- the green body 54 can be sintered at a temperature of 2190 to 2370 degrees F for sintering and densification of the ceramic particles 8, or other suitable temperatures based on the selected ceramic particles 8.
- the sintering advantageously occurs at a temperature sufficiently high to cause the ceramic particles 8 to densify and form into a ceramic.
- the pre-sintering heating advantageously occurs at a temperature that is(i) sufficiently low so as to not fully sinter the ceramic particles 8, but to instead partially sinter the ceramic particles 8 to provide some intermediate strength to the green body 54 via ceramic particle 8 partial densification and (ii) sufficient high to melt or burn off the polymer fugitive 6 and thereby create a space or volume within the ceramic core 10.
- the green body 54 is thereby transformed into a finished multiwall core 10 with the melted or burned off polymer fugitive 6 creating space or volume within the finished multiwall core 10.
- the green body 54 may be further thermally treated to a temperature range of between 1800 to 2400 degrees F to a defined and closely controlled sintering cycle required to produce defect free partially sintered ceramic cores 10.
- the finished multiwall core 10 can be post-sinter processed e.g. to remove extraneous polymer fugitive 6.
- the sintered ceramic particles 8 form a main body 64 portion of the ceramic core 10 while the removed polymer fugitive 6 creates a space or volume defining an internal geometry 66 portion of the multiwall ceramic core 10.
- an exemplary finished multiwall ceramic core 10 generated from a mold 4 made from a master tooling assembly 2 that optionally includes a flexible liner 40 is shown.
- the illustrated multiwall ceramic core 10 is designed and constructed such that the final casting geometry creates detailed, complex and otherwise unmanufacturable internal cooling geometries in the multiwall airfoil 12.
- the illustrated multiwall ceramic core 10 also enables advanced aerodynamic configurations for an advanced external casting geometry of the multiwall airfoil 12.
- FIG. 10 another exemplary finished multi wall ceramic core 10 generated from a mold 4 from a master tooling assembly 2 that optionally does not include a flexible liner 40 is shown.
- the illustrated multiwall ceramic core 10 is designed and constructed such that the final casting geometry creates detailed, complex and otherwise unmanufacturable internal cooling geometries in the multiwall airfoil 12.
- the illustrated multiwall ceramic core 10 also enables advanced aerodynamic configurations for an advanced external casting geometry of the multi wall airfoil 12.
- the finished multi wall ceramic core 10 can then be prepared and cast to create the multiwall airfoil 12.
- the ceramic core 10 can be cast to form the multiwall airfoil 12 in any a variety of casting techniques, including using either an equiaxed or directionally solidified casting process using nickel-based alloys (precipitation hardened or crystallographically engineered for mechanical strength, with the core removeable via mechanical, chemical or other suitable means.
- gas turbine airfoil for use in the power generation industry is illustrated for purposes of this application, as will be understood by those skilled in the art, reference to airfoils, gas turbines and the power industry may also be for other products, processes and industries that may require a core made from a casting process.
- the gas turbine airfoil illustrated above is a contextual example of utilization of various master tooling assemblies and various ceramic cores from which a multiwall component may be made; however, the master tooling assemblies and ceramic cores may be used for any component requiring cast multiwall features.
- the core is often described in context of a ceramic particle material and the fugitive in context of a polymer material, for casting purposes, the core and fugitive may also be of any other materials that function in a similar fashion.
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Abstract
Noyau céramique à parois multiples (10) et procédé de fabrication d'un noyau céramique à parois multiples (10) à l'aide d'une matière fugitive polymère, impliquant une partie de corps principal (64) comprenant une céramique ayant une température de frittage, et une matière fugitive polymère disposée à l'intérieur de la partie de corps principal (64) et encapsulée par celle-ci, la matière fugitive polymère ayant une température de fusion inférieure à la température de frittage de la céramique, mais supérieure à une température requise pour fritter partiellement et densifier la céramique, et la matière fugitive polymère occupant un volume définissant une partie de géométrie interne (66) du noyau céramique à parois multiples (10).
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/US2022/074170 WO2024025597A1 (fr) | 2022-07-27 | 2022-07-27 | Noyau céramique à parois multiples et procédé de fabrication d'un noyau céramique à parois multiples à l'aide d'une matière fugitive polymère |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/US2022/074170 WO2024025597A1 (fr) | 2022-07-27 | 2022-07-27 | Noyau céramique à parois multiples et procédé de fabrication d'un noyau céramique à parois multiples à l'aide d'une matière fugitive polymère |
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WO2024025597A1 true WO2024025597A1 (fr) | 2024-02-01 |
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PCT/US2022/074170 WO2024025597A1 (fr) | 2022-07-27 | 2022-07-27 | Noyau céramique à parois multiples et procédé de fabrication d'un noyau céramique à parois multiples à l'aide d'une matière fugitive polymère |
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WO (1) | WO2024025597A1 (fr) |
Citations (2)
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US20080135718A1 (en) * | 2006-12-06 | 2008-06-12 | General Electric Company | Disposable insert, and use thereof in a method for manufacturing an airfoil |
WO2017160304A1 (fr) * | 2016-03-18 | 2017-09-21 | Siemens Aktiengesellschaft | Procédé de fabrication et outillage pour noyaux en céramique |
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US20080135718A1 (en) * | 2006-12-06 | 2008-06-12 | General Electric Company | Disposable insert, and use thereof in a method for manufacturing an airfoil |
WO2017160304A1 (fr) * | 2016-03-18 | 2017-09-21 | Siemens Aktiengesellschaft | Procédé de fabrication et outillage pour noyaux en céramique |
Non-Patent Citations (1)
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LÓH N J ET AL: "A review of two-step sintering for ceramics", CERAMICS INTERNATIONAL, ELSEVIER, AMSTERDAM, NL, vol. 42, no. 11, 11 May 2016 (2016-05-11), pages 12556 - 12572, XP029579753, ISSN: 0272-8842, DOI: 10.1016/J.CERAMINT.2016.05.065 * |
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