# US 10,245,636 B2 · Method for manufacturing core, and method for manufacturing turbine member in which core is acquired by said core manufacturing method

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- Number: US 10,245,636 B2
- Document ID: US10245636B2
- Status: Granted
- Kind: B2
- Application number: 15/107,277
- Filed: 2015-03-05
- Published: 2017-02-02
- Granted: 2019-04-02
- Earliest claimed: 2014-03-12
- Assignees: Mitsubishi Heavy Industries, Ltd.
- Applicants: Mitsubishi Heavy Industries, Ltd.
- Inventors: Kosuke Fujiwara; Sachio Shimohata; Kazutaka Mori; Hidetaka Oguma; Ikuo Okada; Yoshitaka Uemura
- Web page: https://patentgrep.com/patent/US10245636B2

## CPC

- B22C 9/10: Cores; Manufacture or installation of cores {(breaker cores B22C9/084)}
- B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- Y02P 10/25: Process efficiency
- B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A method for manufacturing a core (S1) includes: a coating step (S20) of adding an organic binder to a large particle group composed of silica-containing large particles, and coating surfaces of the large particles with the organic binder; a mixing step (S30) of mixing, after the coating step (S20), the large particle group and a small particle group composed of silica-containing small particles having a smaller particle size than the large particles; a laminate shaping step (S40) of forming, after the mixing step (S30), a molding in which a mixture of the large and small particle groups is used; and a sintering step (S60) of sintering the molding after the laminate shaping step (S40).

## Claims

### Claim 1

A method for manufacturing a core comprising:
a coating step of adding a binder to a large particle group composed of large particles, and only coating surfaces of the large particles with the binder;
a mixing step of mixing, after the coating step, the large particle group and a small particle group composed of small particles having a smaller particle size than the large particles and not coated with the binder; and
a laminate shaping step of forming, after the mixing step, a molding in which a mixture of the large and small particle groups is used,
wherein particle sizes of the large particles are equal to or more than 10 μm and equal to or less than 50 μm, and particle sizes of the small particles are equal to or more than 0.1 μm and equal to or less than 10 μm.

### Claim 2 (depends on 1)

The method according to claim 1, wherein at least one of the large particles and the small particles contains silica.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the large particle group contains first large particles composed of silica powder and second large particles composed of alumina powder.

### Claim 4 (depends on 1)

The method according to claim 1 wherein the binder is organic matter.

### Claim 5 (depends on 4)

The method according to claim 4, wherein the organic matter contains a phenol resin and aromatic amines.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the coating step comprises inputting the large particle group into a rotary drum, and spraying the binder in liquid form while rotating the rotary drum onto the large particles.

### Claim 7 (depends on 1)

The method according to claim 1, comprising a sintering step of sintering the molding after the laminate shaping step.

### Claim 8 (depends on 7)

The method according to claim 7, wherein the sintering step is carried out at 1200° C. for 15 hours.

### Claim 9 (depends on 8)

The method according to claim 8, wherein the impregnant is a mixture of silica sol and silica, or a mixture of silica sol and alumina.

### Claim 10 (depends on 7)

The method according to claim 7, comprising an impregnating step of impregnating the molding with an impregnant between the laminate shaping step and the sintering step.

### Claim 11 (depends on 1)

A method for manufacturing a turbine member comprising:
a step of acquiring the core using the method according to claim 1; and
a step of removing, after a molten metal fed between the core and a casting mold is solidified, the core to acquire the turbine member having a hollow portion.