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US20210205876A1 - Manufacturing method and tooling for ceramic cores - Google Patents

Manufacturing method and tooling for ceramic cores Download PDF

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Publication number
US20210205876A1
US20210205876A1 US16/070,594 US201616070594A US2021205876A1 US 20210205876 A1 US20210205876 A1 US 20210205876A1 US 201616070594 A US201616070594 A US 201616070594A US 2021205876 A1 US2021205876 A1 US 2021205876A1
Authority
US
United States
Prior art keywords
backing plate
lithographically derived
derived inserts
inserts
lithographically
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
US16/070,594
Other languages
English (en)
Inventor
Gary B. Merrill
Roy Eakins
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Siemens Energy Global GmbH and Co KG
Mikro Systems Inc
RTX Corp
Original Assignee
Siemens AG
Siemens Energy Inc
Mikro Systems Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Siemens AG, Siemens Energy Inc, Mikro Systems Inc filed Critical Siemens AG
Assigned to MIKRO SYSTEMS, INC. reassignment MIKRO SYSTEMS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: EAKINS, Roy
Assigned to SIEMENS ENERGY, INC. reassignment SIEMENS ENERGY, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MERRILL, GARY B.
Publication of US20210205876A1 publication Critical patent/US20210205876A1/en
Assigned to Siemens Energy Global GmbH & Co. KG reassignment Siemens Energy Global GmbH & Co. KG ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SIEMENS AKTIENGESELLSCHAFT
Assigned to SIEMENS AKTIENGESELLSCHAFT reassignment SIEMENS AKTIENGESELLSCHAFT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SIEMENS ENERGY, INC.
Assigned to RTX CORPORATION reassignment RTX CORPORATION CHANGE OF NAME Assignors: RAYTHEON TECHNOLOGIES CORPORATION
Abandoned legal-status Critical Current

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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
    • 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
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft

Definitions

  • the present invention relates to manufacturing advanced ceramic cores and the master tooling for the manufacturing of ceramic cores.
  • 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.
  • cooling fluid such as air discharged from a compressor in the compressor section
  • Effective cooling of turbine airfoils requires delivering the relatively cool air to critical regions such as along the trailing edge of a turbine blade or a stationary vane.
  • the associated cooling apertures may, for example, extend between an upstream, relatively high pressure cavity within the airfoil and one of the exterior surfaces of the turbine blade. Blade cavities typically extend in a radial direction with respect to the rotor and stator of the machine.
  • Airfoils commonly include internal cooling channels which remove heat from the pressure sidewall and the suction sidewall in order to minimize thermal stresses. Achieving a high cooling efficiency based on the rate of heat transfer is a significant design consideration in order to minimize the volume of coolant air diverted from the compressor for cooling.
  • the relatively narrow trailing edge portion of a gas turbine airfoil may include, for example, up to about one third of the total airfoil external surface area.
  • the trailing edge is made relatively thin for aerodynamic efficiency. Consequently, with the trailing edge receiving heat input on two opposing wall surfaces which are relatively close to each other, a relatively high coolant flow rate is entailed to provide the requisite rate of heat transfer for maintaining mechanical integrity.
  • the system to produce master tooling includes multi axis machining of an aluminum block to define the positive surface geometry of one side of a tooling block.
  • an insert is applied to the tooling surface to define advanced tool surface geometry. Due to the non-conformal features, these features are un-machinable.
  • This insert has been manufactured using either bonded photo chemically etched copper foils bonded to make a three dimensional surface or electrical discharge machining (EDM) machined insert.
  • EDM electrical discharge machining
  • a metal alloy component may be cast using a hollow ceramic core.
  • the ceramic core defines the shape of the open volume when the component is cast within an outer casting shell.
  • a tooling assembly for ceramic cores comprises: a backing plate comprising a top surface, side surfaces, and a bottom surface; a plurality of lithographically derived inserts each comprising a bottom surface, side surfaces, and a positive top surface, wherein the plurality of lithographically derived inserts are pieced together on the top surface of the backing plate; a second backing plate comprising a top surface, side surfaces, and a bottom surface; and a second plurality of lithographically derived inserts each comprising a bottom surface, side surfaces, and a positive top surface, wherein the plurality of lithographically derived inserts are pieced together on the top surface of the second backing plate.
  • a method of manufacturing of a tooling assembly for ceramic cores comprises: providing a plurality of lithographically derived inserts and a second plurality of lithographically derived inserts each comprising a bottom surface, side surfaces, and a positive top surface; providing a backing plate and a second backing plate each comprising a top surface, side surfaces, and a bottom surface, the backing plate and the second backing plate provided as a locator surface; generating a non-conformal positive surface from the plurality of lithographically derived inserts pieced together and placed on the backing plate; generating a non-conformal positive surface from the second plurality of lithographically derived inserts pieced together and placed on the second backing plate; creating a first negative flexible mold from the non-conformal positive surface of the plurality of lithographically derived inserts; creating a second negative flexible transfer mold from the non-conformal positive surface of the second plurality of lithographically derived inserts; and preparing the negative flexible
  • FIG. 1 is a perspective view of lithographically derived inserts of the exemplary embodiments of the present invention
  • FIG. 2 is a perspective view of a schematic of a portion of a master tooling assembly with lithographically derived inserts in an exemplary embodiment of the present invention.
  • FIG. 3 is a side view of a schematic of a master tooling assembly in an exemplary embodiment of the present invention.
  • a method of manufacturing a tooling assembly and the tooling assembly for ceramic cores includes a backing plate comprising a top surface and a plurality of lithographically derived inserts pieced together on the top surface of the backing plate.
  • the method includes providing the backing plate and plurality of lithographically derived inserts.
  • a non-conformal positive surface is generated from the plurality of lithographically derived inserts.
  • a negative flexible mold is created from the non-conformal positive surface. The negative flexible mold is then prepared for casting for an advanced ceramic core.
  • gas turbine engines are required to provide movement to produce electricity in a generator.
  • 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.
  • Modern engines and certain components such as airfoils, e.g. stationary vanes and rotating blades within the turbine section, implement high pressure ratios and high engine firing temperatures. As advancements are made, components are seeing higher and higher temperatures and require more and more expensive materials to produce these components.
  • any reference to a ceramic material may also be any other material that functions in a similar fashion.
  • the reference to turbines and the power industry may also be for other processes and products that may require a core made from a casting process.
  • Producing a blade can require first a production of a mold. The mold is produced from a master tooling surface.
  • Embodiments of the present invention provide a method of manufacturing that may allow for the reduction of cost in manufacturing a master tooling assembly as well as the master tooling assembly itself.
  • the turbine blade and airfoil are used below as an example of the method and tooling assembly; however, the method and tooling assembly may be used for any component requiring detailed features along a core for casting purposes.
  • the turbine blade can be within the power generation industry.
  • the method and tooling assembly mentioned below may be in conjunction with a process that starts with a 3D computer model of a part to be created. From the model a solid surface is created from which a flexible mold can be created that is used in conjunction with a second mating flexible mold to form a mold cavity.
  • the flexible mold is created from a machined master tool representing roughly fifty percent of the surface geometry of the core to be created. From such a tool, a flexible transfer mold can be created.
  • a second half of the master tool that creates a second flexible transfer mold can be combined with the first flexible transfer mold to form the mold cavity. From such a mold cavity a curable slurry can be applied to create a three dimensional component form.
  • An example of such a form can be a ceramic core used for investment casting.
  • materials of construction can be specifically selected to work in cooperation with the casting and firing processes to provide a core that overcomes known problems with prior art cores.
  • the materials and processes of embodiments of the present invention may result in a ceramic body which is suitable for use in a conventional metal alloy casting process.
  • a master tooling assembly 10 may be produced with a backing plate 12 and a plurality of lithographically derived inserts 14 .
  • Precision machined surfaces produced from computer numerical control (CNC) machines are replaced with the plurality of lithographically derived inserts 14 and backing plate 12 .
  • a single step machined surface, the backing plate 12 may serve as a locator surface for the plurality of lithographically derived inserts 14 pieced together to define a master tooling surface 22 .
  • 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 12 may be a single step machined surface.
  • the backing plate 12 may include a top surface 20 , side surfaces 18 , and a bottom surface 16 .
  • the plurality of lithographically derived inserts 14 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 14 may include a bottom surface 24 , side surfaces 26 , and a positive top surface 28 , that may become the master tooling surface 22 .
  • the positive top surface 28 may be non-conformal.
  • the plurality of lithographically derived inserts 14 may expand across the entire top surface 20 of backing plate 12 .
  • the plurality of lithographically derived inserts 14 may include various amounts of pieces.
  • the plurality of lithographically derived inserts 12 includes three through eight inserts. The amount of plurality of lithographically derived inserts 14 may depend upon the complexity of the surface geometry and the degree of flexibility requested.
  • a method of manufacturing the master tooling assembly 10 for ceramic cores may include providing the plurality of lithographically derived inserts 14 .
  • the backing plate 12 may be provided as a locating surface for the plurality of lithographically derived inserts 14 .
  • the plurality of lithographically derived inserts 14 may be pieced together and placed on the backing plate 12 .
  • the precision thin layer bonding may be with accomplished with a reversible thin layer bonding media.
  • the backing plate 12 may include suction ports located in the top of the plate 20 . Once the plurality of lithographically derived inserts 14 is set in position along the backing plate 12 , a portion of the master tooling assembly 10 may be complete.
  • the plurality of lithographically derived inserts 14 and the backing plate 12 may form a first half 32 of a master tool.
  • a second half 34 of the master tool may be formed by a second plurality of lithographically derived inserts 14 and a second backing plate 38 .
  • the second backing plate 38 may include a top surface 20 , side surfaces 18 , and a bottom surface 16 .
  • the second half 34 of the master tool may be combined with the first half 32 of the master tool to form a mold cavity. The combining of the first half 32 and the second half 34 of the master tool provides the master tooling assembly 10 .
  • Two negative flexible transfer molds may be created from the non-conformal positive surfaces of the plurality of lithographically derived inserts 14 and a second plurality of lithographically derived inserts 36 respectively.
  • the negative flexible transfer molds may then be combined to produce a mold cavity into which a slurry can be introduced and cured to create a ceramic green body (ceramic core).
  • the advanced ceramic core may be used for the investment casting of an advanced turbine blade.
  • the second plurality of lithographically derived inserts 36 and the second backing plate 38 have the same properties as the plurality of lithographically derived inserts 14 and the backing plate 12 except for the second plurality of lithographically derived inserts 36 may have different non-conformal positive surfaces.
  • Each of the second plurality of lithographically derived inserts 36 may include a bottom surface 24 , side surfaces 26 , and a positive top surface 28 , that may become the master tooling surface 22 .
  • the backing surface may be a single step machined surface.
  • Each of the plurality of lithographically derived inserts 14 and second plurality of lithographically derived inserts 36 may be interchanged for other lithographically derived inserts 14 , 36 for minor changes.
  • this method with interchangeable plurality of lithographically derived inserts 14 and second plurality of lithographically derived inserts 36 allows for quick adjustments.
  • the tooling assembly being readily adjustable, allows for a reduction in manufacturing costs and reduces the time in between required changes.
  • FIG. 1 shows an example of advanced detailed features 30 of the plurality of lithographically derived inserts 14 for a turbine component.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
US16/070,594 2016-03-18 2016-03-18 Manufacturing method and tooling for ceramic cores Abandoned US20210205876A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2016/023017 WO2017160304A1 (fr) 2016-03-18 2016-03-18 Procédé de fabrication et outillage pour noyaux en céramique

Related Parent Applications (1)

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PCT/US2016/023017 A-371-Of-International WO2017160304A1 (fr) 2016-03-18 2016-03-18 Procédé de fabrication et outillage pour noyaux en céramique

Related Child Applications (1)

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US17/483,429 Continuation US11541452B2 (en) 2016-03-18 2021-09-23 Manufacturing method and tooling for ceramic cores

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US20210205876A1 true US20210205876A1 (en) 2021-07-08

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US17/483,429 Active US11541452B2 (en) 2016-03-18 2021-09-23 Manufacturing method and tooling for ceramic cores

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US (2) US20210205876A1 (fr)
EP (1) EP3429779B1 (fr)
CN (1) CN108778561B (fr)
WO (1) WO2017160304A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
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WO2021086391A1 (fr) 2019-11-01 2021-05-06 Siemens Energy Global GmbH & Co. KG Procédé de fabrication d'outillage souple pour la coulée d'un noyau céramique
WO2024025596A1 (fr) * 2022-07-27 2024-02-01 Siemens Energy, Inc. Noyau en céramique à parois multiples et procédé de fabrication d'un noyau en céramique à parois multiples à l'aide d'une matière fugitive en céramique non frittable
EP4547426A1 (fr) * 2022-07-27 2025-05-07 Siemens Energy, Inc. 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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Also Published As

Publication number Publication date
CN108778561A (zh) 2018-11-09
CN108778561B (zh) 2021-01-05
EP3429779B1 (fr) 2020-06-03
US20220008986A1 (en) 2022-01-13
EP3429779A1 (fr) 2019-01-23
US11541452B2 (en) 2023-01-03
WO2017160304A1 (fr) 2017-09-21

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Owner name: MIKRO SYSTEMS, INC., VIRGINIA

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:EAKINS, ROY;REEL/FRAME:049449/0444

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Owner name: SIEMENS ENERGY, INC., FLORIDA

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