[미국특허]
Disposable insert, and use thereof in a method for manufacturing an airfoil
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B22C-009/00
B22C-009/10
출원번호
UP-0567443
(2006-12-06)
등록번호
US-7624787
(2009-12-16)
발명자
/ 주소
Lee, Ching Pang
Wang, Hsin Pang
Upadhyay, Ram Kumar
Myers, Paul Richard
Edgar, Marc Thomas
출원인 / 주소
General Electric Company
대리인 / 주소
Clarke, Penny A.
인용정보
피인용 횟수 :
22인용 특허 :
37
초록▼
A method of forming an integral casting core includes adding a disposable insert to a metal core die and disposing a slurry into the metal core die. The slurry includes ceramic particles. The method further includes firing the slurry to form a integral casting core and removing the disposable insert
A method of forming an integral casting core includes adding a disposable insert to a metal core die and disposing a slurry into the metal core die. The slurry includes ceramic particles. The method further includes firing the slurry to form a integral casting core and removing the disposable insert from the integral casting core.
대표청구항▼
What is claimed is: 1. A method of forming an integral casting core comprising: adding a disposable insert to a metal core die, wherein the disposable insert defines a partition wall in a double wall airfoil; disposing a slurry into the metal core die; wherein the slurry comprises ceramic particles
What is claimed is: 1. A method of forming an integral casting core comprising: adding a disposable insert to a metal core die, wherein the disposable insert defines a partition wall in a double wall airfoil; disposing a slurry into the metal core die; wherein the slurry comprises ceramic particles; firing the slurry to form an integral casting core, wherein the integral casting core is formed via a single step of disposing the slurry into the metal core die; and removing the disposable insert from the integral casting core. 2. The method of claim 1, wherein the removal of the disposable insert is accomplished via chemical dissolution, chemical degradation, mechanical abrasion, melting, thermal degradation or a combination comprising at least one of the foregoing methods of removing. 3. The method of claim 1, wherein the disposable insert is manufactured by a rapid prototyping process. 4. The method of claim 1, further comprising curing the slurry to form a cured ceramic core. 5. The method of claim 4, wherein the curing of the slurry is conducted prior to the firing of the slurry. 6. The method of claim 1, wherein the removal of the disposable insert comprises degrading the disposable insert. 7. The method of claim 1, further comprising disposing the integral casting core into a wax die; wherein the wax die comprises a metal. 8. The method of claim 7, further comprising injecting a wax into the wax die to form a wax component. 9. The method of claim 8, further comprising immersing the wax component into a slurry to form an outer shell; and firing the wax component with the outer shell to form a ceramic shell. 10. The method of claim 8, wherein the slurry comprises a ceramic. 11. The method of claim 8, further comprising removing the wax from the outer shell and the wax component. 12. The method of claim 11, further comprising disposing a molten metal into the outer shell. 13. The method of claim 12, further comprising removing the outer shell and an integral casting core to yield a molded component. 14. A double wall airfoil comprising a partition wall manufactured by the method of claim 1. 15. The double wall airfoil of claim 14, wherein the double wall airfoil is a turbine component. 16. A method comprising: adding a disposable insert to a metal core die; wherein the disposable insert comprises a wax and defines a partition wall in a double wall airfoil; disposing a slurry in to the metal core die; wherein the slurry comprises ceramic particles; firing the slurry in a first firing process to form an integral casting core; wherein the disposable insert is removed from the integral casting core during the firing of the slurry, and wherein the integral casting core is formed via a single step of disposing the slurry into the metal core die; disposing the integral casting core into a wax die; wherein the wax die comprises a metal surface; injecting a wax into the wax die to form a wax component; immersing the wax component into a slurry to form an outer shell; firing the wax component with the outer shell in a second firing process to form a ceramic shell; removing the wax from the outer shell and the wax component; disposing a molten metal into the outer shell; and removing the outer shell to yield a molded component. 17. The method of claim 16, wherein the molded component is a turbine airfoil. 18. The method of claim 16, wherein the disposable insert comprises a wax. 19. The method of claim 16, wherein the disposable insert comprises an organic polymer. 20. The method of claim 19, wherein the organic polymer is a thermoplastic polymer, a thermo setting polymer, a blend of thermoplastic polymers, or blends of thermoplastic polymers with thermo setting polymers. 21. The method of claim 19, wherein the organic polymer is a homopolymer, a copolymer, a star block copolymer, a graft copolymer, an alternating block copolymer, a random copolymer, an ionomer, a dendrimer, or a combination comprising at least one of the foregoing types of organic polymers. 22. The method of claim 21, wherein the organic polymer is a blend of polymers, copolymers, terpolymers, or a combination comprising at least one of the foregoing types of organic polymers.
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