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AssigneeHowmet Corporation
InventorsBoyd A. Mueller, Michael A. Pepper, Daren K. Rogers, Gail R. Cole
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A method is provided for making a mold for casting advanced turbine airfoils (e.g. gas turbine blade and vane castings) which can include complex internal and external air cooling features to improve efficiency of airfoil cooling during operation in the gas turbine hot gas stream. The method steps involve incorporating at least one fugitive insert in a ceramic material in a manner to form a core and at least a portion of an integral, cooperating mold wall wherein the core defines an internal cooling feature to be imparted to the cast airfoil and the at least portion of the mold wall has an inner surface that defines an external cooling feature to be imparted to the cast airfoil, selectively removing the fugitive insert, and incorporating the core and the at least portion of the integral, cooperating mold wall in a mold for receiving molten metal or alloy cast in the mold.
A method of making a mold for casting a metal or alloy article, comprising the steps of incorporating at least one fugitive insert in a ceramic material in a manner to form a core and at least a portion of an integral, cooperating mold wall wherein the core defines an internal feature to be imparted to the cast article and the at least portion of the mold wall has an inner surface that defines an external feature to be imparted to the cast article, selectively removing the fugitive insert, and incorporating the core and the at least portion of the integral, cooperating mold wall in a mold for receiving molten metal or alloy.
A method of casting a metal or alloy turbine airfoil, comprising the steps of incorporating at least one fugitive insert in a ceramic material in a manner to form a core and at least a portion of an integral, cooperating mold wall wherein the core defines an internal cooling feature to be imparted to the cast airfoil and the at least portion of the mold wall has an inner surface that defines an external cooling feature to be imparted to the cast airfoil, selectively removing the fugitive insert, selectively removing the fugitive insert, incorporating the core and the at least portion of the integral, cooperating mold wall in a mold, and solidifying a molten metal or alloy in the mold wall about the core.
A ceramic component for casting an article, comprising a ceramic core that is configured to define an internal feature to be imparted to the cast article and that is connected integrally to at least a portion of a cooperating mold wall having an inner surface defining an external feature to be imparted to the cast article.
A cast metal or alloy turbine airfoil having a ceramic component remaining thereon after casting, wherein the ceramic component comprises a ceramic core that is configured to define an internal cooling passage in the turbine airfoil and that is connected integrally to at least a portion of a cooperating mold wall having an inner surface defining an external cooling feature of the turbine airfoil.
Dependencies are inferred from the claim text.