Cast components and manufacture and use methods

Patent metadata

Field	Value
Publication number	US-10315241-B2
Application number	US-201514748688-A
Country	US
Kind code	B2
Filing date	Jun 24, 2015
Priority date	Jul 1, 2014
Publication date	Jun 11, 2019
Grant date	Jun 11, 2019

Abstract

A method comprises: providing a spiral metallic workpiece having a cast structure associated with such spiral; and at least partially flattening the workpiece.

First claim

What is claimed is:

1. A method comprising:
making a spiral cut in a precursor metallic workpiece, the spiral is about a spiral axis within 5° of a crystallographic axis of the precursor metallic workpiece to form a spiral metallic workpiece; and
at least partially flattening the spiral metallic workpiece by unrolling, wherein the at least partially flattened spiral metallic workpiece has two free ends.

2. The method of claim 1 wherein:
the spiral metallic workpiece has a modified single crystal (SX) structure characterized by a progressively circumferentially varying absolute crystallographic orientation.

3. The method of claim 2 wherein:
the progressively circumferentially varying absolute crystallographic orientation is provided by casting over a circumferential array of seeds.

4. The method of claim 1 further comprising:
securing the two free ends of the at least partially flattened spiral metallic workpiece to each other or to ends of other similar workpieces so as to form a full hoop.

5. The method of claim 4 wherein:
the securing comprises welding.

6. The method of claim 1 further comprising:
casting the precursor metallic workpiece.

7. The method of claim 6 wherein:
the casting comprises withdrawing the precursor metallic workpiece in a direction within 1° of parallel to the spiral axis.

8. The method of claim 1 wherein:
the spiral metallic workpiece has a single crystal (SX) structure.

9. The method of claim 1 wherein:
a <001> or <111> direction of the spiral metallic workpiece is within 3° of the spiral axis.

10. The method of claim 1 wherein:
the precursor metallic workpiece is formed as a right circular cylinder.

11. The method of claim 1 wherein:
the precursor metallic workpiece is formed as a hollow right circular cylinder.

12. The method of claim 1 wherein:
the spiral metallic workpiece is a nickel-based superalloy.

13. A method comprising:
casting a metal alloy over a spiral core so that the spiral core forms an as-cast gap in the metal alloy;
solidifying the metal alloy so that a spiral is about a spiral axis within 10° of a crystallographic axis of the solidified metal alloy to provide a spiral metallic workpiece; and
at least partially flattening the spiral metallic workpiece by unrolling, wherein the at least partially flattened spiral metallic workpiece has two free ends.

14. The method of claim 13 wherein:
the casting comprises forming a mold by shelling the spiral core.

15. The method of claim 14 further comprising:
forming the spiral core by bending a refractory metal sheet and ceramic coating the sheet.

16. The method of claim 14 further comprising:
forming the spiral core by rolling into a spiral a sandwich of a cloth sheet and wax.

17. The method of claim 13 wherein:
the spiral metallic workpiece has a modified single crystal (SX) structure characterized by a progressively circumferentially varying absolute crystallographic orientation.

18. The method of claim 17 wherein:
the progressively circumferentially varying absolute crystallographic orientation is provided by casting over a circumferential array of seeds.

19. The method of claim 13 wherein:
the spiral metallic workpiece has a single crystal (SX) structure.

20. The method of claim 13 wherein:
a <001> or <111> direction of the spiral metallic workpiece is within 5° of the spiral axis.

Assignees

• United Technologies Corp

Inventors

• Shah Dilip M
• Cetel Alan D
• Marcin Jr John J
• Bullied Steven J
• Verner Carl R

Classifications

• C30B29/52

  Alloys · CPC title

• B22D21/00

  Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor {(non-ferrous ingots B22D7/005)} · CPC title

• C30B11/002 Primary

  Crucibles or containers for supporting the melt · CPC title

• Y10T29/49989

  Followed by cutting or removing material · CPC title

• B23P15/02

  turbine or like blades from one piece · CPC title