Method of forming hollow channels within a component
AssigneeGeneral Electric Company
InventorsJi-Cheng Zhao, Melvin Robert Jackson, Paul Leonard Dupree, James Ross Dobbs
Life of this patent
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Abstract
A method of forming an internal channel within an article, such as a cooling channel in an air-cooled blade, vane, shroud, combustor or duct of a gas turbine engine. The method generally entails forming a substrate to have a groove recessed in its surface. A sacrificial material is then deposited in the groove to form a filler that can be preferentially removed from the groove. A permanent layer is then deposited on the surface of the substrate and over the filler, after which the filler is removed from the groove to yield the desired channel in the substrate beneath the permanent layer.
Claims19
A method of forming an internal channel in an article, the method comprising the steps of:
- forming a substrate having a surface and a groove recessed in the surface;
- depositing a paste in the groove so as to fill the groove, the paste comprising a sacrificial material in a binder, the sacrificial material being chosen from the group consisting of KBO2, NiCl2, MgSO4, NiF2, NaAlO2, and mixtures of NaAlO2 and NaAlSiO4;
- removing the binder so as to leave the sacrificial material in the groove, the sacrificial material defining a fill surface that is substantially coplanar with the surface of the substrate;
- depositing a permanent layer on the surface of the substrate and over the sacrificial material in the groove;
- and then
- removing the sacrificial material from the groove so as to form an internal channel in the substrate and beneath the permanent layer.
A method of forming an internal channel in an article, method comprising the steps of:
- forming a substrate having a surface and a groove recessed in the surface;
- consolidating a sacrificial material into the groove so as to fill the groove at a temperature of less than 200° C., the sacrificial material being chosen from the group consisting of KBr, NiBr2, BN, and mixtures of talc and pyrophyllite, the sacrificial material defining a fill surface that is substantially coplanar with the surface of the substrate;
- depositing a permanent layer on the surface of the substrate and over the sacrificial material in the groove;
- and then
- removing the sacrificial material from the groove so as to form an internal channel in the substrate and beneath the permanent layer.
A method of forming an internal channel in an article, the method comprising the steps of:
- forming a substrate having a surface and a groove recessed in the surface;
- depositing and sintering a sacrificial material in the groove so as to fill the groove, the sacrificial material being chosen from the group consisting of MgF2, NiF2, and mixtures of talc and pyrophyllite, the sacrificial material defining a fill surface that is substantially coplanar with the surface of the substrate;
- depositing a permanent layer on the surface of the substrate and over the sacrificial material in the groove;
- and then
- removing the sacrificial material from the groove so as to form an internal channel in the substrate and beneath the permanent layer.
A method of forming an internal channel in an article, the method comprising the steps of:
- forming a substrate having a surface and a groove recessed in the surface;
- depositing a sacrificial material in the groove so as to fill the groove, the sacrificial material being chosen from the group consisting of MoO3 and substances with sublimation temperatures between about 500° C. and 1100° C., the sacrificial material defining a fill surface that is substantially coplanar with the surface of the substrate;
- depositing a first permanent layer on the surface of the substrate and over the sacrificial material in the groove;
- heating the sacrificial material to remove the sacrificial material from the groove by sublimation so as to form an internal channel in the substrate and beneath the first permanent layer;
- and then.
- depositing a second permanent layer on the first permanent layer, the first permanent layer being more compliant than the second permanent layer.
A method of forming an internal channel in an article, the method comprising the steps of:
- forming a substrate having a surface and a groove recessed in the surface;
- depositing a paste in the groove so as to fill the groove, the paste comprising a sacrificial material in a binder, the sacrificial material being chosen from the group consisting of NaCl, KBO2, NiCl2, MgSO4, NiF2, NaAlO2, and mixtures of NaAlO2 and NaAlSiO4;
- removing the binder so as to leave the sacrificial material in the groove, the sacrificial material defining a fill surface that is substantially coplanar with the surface of the substrate;
- depositing a permanent layer on the surface of the substrate and over the sacrificial material in the groove;
- and then
- removing the sacrificial material from the groove so as to form an internal channel in the substrate and beneath the permanent layer.
A method of forming an internal channel in a component of a turbine engine, comprising the steps of:
- forming a substrate having a surface and a groove recessed in the surface;
- depositing a paste in the groove so as to fill the groove, the paste comprising a sacrificial material in a binder, wherein the sacrificial material is compositionally stable at a temperature of at least about 1200° C.;
- removing the binder so as to leave the sacrificial material in the groove, the sacrificial material defining a fill surface that is substantially coplanar with the surface of the substrate;
- depositing a permanent layer on the surface of the substrate and over the sacrificial material in the groove, using electron-beam physical vapor deposition;
- and then
- removing the sacrificial material from the groove, so as to form an internal channel in the substrate and beneath the permanent layer.
Dependencies are inferred from the claim text.