# US 9,038,700 B2 · Process and refractory metal core for creating varying thickness microcircuits for turbine engine components

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- Number: US 9,038,700 B2
- Document ID: US9038700B2
- Status: Granted
- Kind: B2
- Application number: 13/708,036
- Filed: 2012-12-07
- Published: 2013-04-18
- Granted: 2015-05-26
- Earliest claimed: 2009-02-17
- Assignees: United Technologies Corporation
- Applicants: United Technologies Corporation
- Inventors: Bryan P. Dube; Ryan Shepard Levy; Richard H. Page
- Web page: https://patentgrep.com/patent/US9038700B2

## CPC

- B22C 9/10: Cores; Manufacture or installation of cores {(breaker cores B22C9/084)}
- B22C 9/04: Use of lost patterns
- B22C 9/108: {Installation of cores}
- B22D 29/001: {Removing cores}
- F01D 5/187: {Convection cooling}
- F05D 2230/00: Manufacture
- F05D 2230/21: by casting
- F05D 2240/121: related to the leading edge of a stator vane
- F05D 2240/122: related to the trailing edge of a stator vane
- F05D 2240/303: related to the leading edge of a rotor blade
- F05D 2240/304: related to the trailing edge of a rotor blade
- F05D 2250/185: serpentine-like
- F05D 2300/13: Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
- B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B)
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS

## Abstract

The present disclosure is directed to a refractory metal core for use in forming varying thickness microcircuits in turbine engine components, a process for forming the refractory metal core, and a process for forming the turbine engine components. The refractory metal core is used in the casting of a turbine engine component. The core is formed by a sheet of refractory metal material having a curved trailing edge portion integrally formed with a leading edge portion.

## Claims

### Claim 1

A process of forming a turbine engine component comprising the steps of:
providing only one non-ceramic core formed from a single sheet of refractory metal material;
said non-ceramic core providing step comprising providing the single sheet of refractory metal material core having at least one portion for forming at least one as-cast cooling circuit within said turbine engine component;
said refractory metal material core providing step comprising machining the single sheet of refractory metal material core into a first portion for forming a serpentine cooling circuit in said turbine engine component and machining a second portion for forming a trailing edge cooling circuit in said turbine engine component, machining said sheet of refractory metal material core into a third portion for forming a leading edge cooling circuit in said turbine engine component, machining said sheet of refractory metal material core into a fourth portion for forming at least one internal cooling passage for said turbine engine component, wherein said first portion is integral to said second, third, and fourth portions;
providing a mold having a shape of said turbine engine component;
positioning only said non-ceramic core within said mold;
introducing a molten metal material into said mold and allowing said molten metal material to solidify and form said turbine engine component; and
removing said non-ceramic core from said solidified turbine engine component.

### Claim 2 (depends on 1)

The process according to claim 1, wherein said refractory metal material core providing step comprises providing the single sheet of refractory metal material from molybdenum having a varying thickness.

### Claim 3 (depends on 1)

The process according to claim 1, wherein said refractory metal material core providing step comprises providing the single sheet of refractory metal material from molybdenum alloy having a varying thickness.

### Claim 4

A process of forming a refractory metal core for use in a turbine engine component casting system comprising the steps of:
providing a single sheet of refractory metal material having a substantially flat side;
subjecting said single sheet of refractory metal material to an operation to alter a curvature in said single sheet of refractory metal material and form a curved trailing edge portion; and
fabricating said single sheet of refractory metal material to have different thicknesses in different portions,
wherein said fabricating step comprises removing material so as to form a first portion with a serpentine configuration and removing material from a trailing edge portion of said single sheet of refractory metal material so as to form a second portion in a shape of a trailing edge cooling circuit;
wherein said fabricating step further comprises removing material from said single sheet to form a third portion for forming a leading edge cooling microcircuit and a fourth portion for forming an integral cooling microcircuit located between said third portion and said first portion.

### Claim 5 (depends on 4)

The process according to claim 4, wherein said subjecting step comprises subjecting said sheet of refractory metal material to a rolling operation.

### Claim 6 (depends on 4)

The process according to claim 4, wherein said fabricating step comprises removing portions of said single sheet of refractory metal material to form the core having a curvature at one edge.

### Claim 7 (depends on 4)

The process according to claim 4, wherein said fabricating step comprises removing material to form an array of pedestal shaped members.

### Claim 8 (depends on 4)

The process according to claim 4, wherein said fabricating step comprises removing material to form an array of trip strip members.

### Claim 9 (depends on 4)

The process according to claim 4, wherein said fabricating step comprises removing material so as to form said first portion of said core in a shape of said serpentine cooling circuit and said second portion, integrally connected to said first portion, in the shape of said trailing edge cooling circuit.

### Claim 10 (depends on 4)

The process of claim 4, wherein said refractory metal material providing step comprises providing the single sheet of material formed solely from one of molybdenum and a molybdenum alloy.