Cooled turbine blade cast tip recess
AssigneeHoneywell International Inc.
InventorsMark C. Morris, Steve H. Halfmann, Jason C. Smoke
Life of this patent
Estimating the term…
Abstract
A core assembly including two cores is used to manufacture a blade. The first core has an outer surface shaped to complement the tip wall bottom surface. The second core has a tip surface, a side surface, and a protrusion or a depression. The tip surface is shaped to complement at least a portion of the tip wall top surface and is configured to be disposed proximate the first core. The side surface is shaped to complement at least a portion of the side wall, and the protrusion extends from the second core side surface to contact at least a portion of the ceramic mold inner surface. In embodiments employing a depression, the depression is formed in the side surface.
Claims16
A method of manufacturing an air-cooled turbine blade having an outer surface, side walls and a tip wall, the side walls having tip edges, the tip wall extending between the side walls and recessed a predetermined distance from the tip edges to form a tip recess, the tip wall having a bottom surface and a top surface, the top surface defining a portion of the tip recess, the method comprising the steps of:
- forming a ceramic mold around a first core and a second core that are adjacent one another, the ceramic mold having an inner surface shaped to complement at least a portion of the turbine blade outer surface and defining a cavity, the first and second cores disposed in the cavity, the first core having an outer surface shaped to complement the tip wall bottom surface, the second core having a tip surface, a side surface, and a protrusion, the tip surface shaped to complement at least a portion of the tip wall top surface and disposed proximate the first core outer surface, the side surface shaped to complement at least a portion of the side wall, and the protrusion extending from the second core side surface to contact at least a portion of the ceramic mold inner surface;
- injecting metal into the ceramic mold cavity to at least partially cover the first and second cores;
- separating a first portion of the second core and a portion of the metal and ceramic mold surrounding the second core first portion from a second portion of the second core, the first portion including the protrusions and a first portion of the side surface and the second portion including the tip surface and a second portion of the side surface adjacent the tip surface;
- and
- removing the second portion of the core and the ceramic mold from the metal to expose the tip recess.
A method of manufacturing an air-cooled turbine blade having an outer surface, side walls, and a tip wall, the side walls having tip edges, the tip wall extending between the side walls and recessed a predetermined distance from the tip edges to form a tip recess, the tip wall having a bottom surface and a top surface, the top surface defining a portion of the tip recess, the method comprising the steps of:
- forming a ceramic mold around a first core and a second core that are adjacent one another, the ceramic mold having an inner surface shaped to complement at least a portion of the turbine blade outer surface and defining a cavity, the first and second cores disposed in the cavity, the first core having an outer surface shaped to complement the tip wall bottom surface, the second core having a tip surface, a side surface, and a depression, the tip surface shaped to complement at least a portion of the tip wall top surface, the side surface shaped to complement at least a portion of the side wall, and the depression formed in the second core side surface;
- placing a locator pin in the depression and in contact with at least a portion of the ceramic mold inner surface;
- injecting metal into the ceramic mold cavity to at least partially cover the first and second cores and the locator pin;
- separating a first portion of the second core and a portion of the metal and ceramic mold surrounding the second core first portion from a second portion of the second core, the first portion including the depressions and the locator pin, and a first portion of the side surface and the second portion including the tip surface and a second portion of the side surface adjacent the tip surface;
- and
- removing the second portion of the core and the ceramic mold from the metal to expose the tip recess.
A core assembly for disposal in a cavity of a ceramic mold, the ceramic mold having an inner surface shaped to complement an outer surface of a turbine blade, the turbine blade further including having an outer surface, side walls, and a tip wall, the side walls having tip edges, the tip wall extending between the side walls and recessed a predetermined distance from the tip edges to form a tip recess, the tip wall having a bottom surface and a top surface, the top surface defining a portion of the tip recess, the assembly comprising:
- a first core having an outer surface shaped to complement the tip wall bottom surface;
- and
- a second core having a tip surface, a side surface, and a protrusion, the tip surface shaped to complement at least a portion of the tip wall top surface and configured to be disposed proximate the first core, the side surface shaped to complement at least a portion of the side wall, and the protrusion extending from the second core side surface configured to contact at least a portion of the ceramic mold inner surface.
A core assembly for disposal in a cavity of a ceramic mold, the ceramic mold having an inner surface shaped to complement an outer surface of a turbine blade, the turbine blade further including having an outer surface, side walls, and a tip wall, the side walls having tip edges, the tip wall extending between the side walls and recessed a predetermined distance from the tip edges to form a tip recess, the tip wall having a bottom surface and a top surface, the top surface defining a portion of the tip recess, the assembly comprising:
- a first core having an outer surface shaped to complement the tip wall bottom surface;
- a second core having a tip surface, a side surface, and a depression, the tip surface shaped to complement at least a portion of the tip wall top surface and configured to be disposed in contact with the first core standoff point, the side surface shaped to complement at least a portion of the side wall, and the depression formed in the second core side surface configured to receive a portion of a locator pin including an end configured to contact at least a portion of the ceramic mold inner surface.
Dependencies are inferred from the claim text.