Arcuate directionally solidified components and manufacture methods

Patent metadata

Field	Value
Publication number	US-10369625-B2
Application number	US-201514731768-A
Country	US
Kind code	B2
Filing date	Jun 5, 2015
Priority date	Jun 6, 2014
Publication date	Aug 6, 2019
Grant date	Aug 6, 2019

Abstract

A method for casting comprising: providing a seed, the seed characterized by: an arcuate form and a crystalline orientation progressively varying along an arc of the form; providing molten material; and cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

First claim

What is claimed is:

1. A method for casting comprising:
providing a seed, the seed characterized by:
an arcuate form and a crystalline orientation progressively varying relative to a fixed frame of reference along an arc of the form;

providing molten material; and
cooling and solidifying the molten material so that a crystalline structure of the seed propagates into the solidifying material.

2. The method of claim 1 further comprising:
partially melting the seed.

3. The method of claim 1 wherein the cooling and solidifying comprises:
passing a solidification front through an arcuate planform passageway passing radially back and forth in a non-line-of-sight manner.

4. The method of claim 1 wherein:
the seed has a weld or braze joint.

5. The method of claim 4 wherein:
the weld or braze joint is partial height.

6. The method of claim 1 wherein:
the seed is a full annulus.

7. The method of claim 1 further comprising forming the seed by:
casting at least one precursor of the seed; and
bending the at least one precursor into said arcuate form.

8. The method of claim 1 further comprising forming the seed by:
bending at least one precursor of the seed into said arcuate form.

9. The method of claim 8 wherein:
the bending is by at least 40°.

10. The method of claim 1 further comprising forming the seed by:
assembling end-to-end a plurality of arcuate segments.

11. The method of claim 10 wherein:
two to eight said segments combine to encircle at least 350° about a central longitudinal axis of the seed.

12. The method of claim 10 wherein the assembling comprises one or more of:
clamping;
welding; and
brazing.

13. The method of claim 10 wherein the assembling comprises:
tack welding.

14. The method of claim 1 wherein:
the providing the molten material comprises pouring a molten metal.

15. The method of claim 14 further comprising:
forging the solidified metal; and
machining the forged metal.

16. The method of claim 15 wherein:
a pre-forging height to diameter ratio is not greater than 1.0.

17. The method of claim 15 further comprising:
ring rolling the solidified metal; and
machining the rolled metal.

18. The method of claim 1 wherein the article is one of:
a turbine engine disk or component thereof;
a blade outer air seal;
a combustor panel; or
an engine case or component thereof.

19. The method of claim 1 wherein:
the cooling and solidifying comprises downwardly shifting a shell.

20. The method of claim 1 wherein:
the cooling and solidifying comprises upwardly drawing from a melt pool.

21. The method of claim 1 wherein:
the providing the molten material comprises a local melting with a heat source moving relative to the seed to melt material while leaving solid material above and below the melted material.

22. A disk manufacture method, comprising:
casting a first component according to the method of claim 1 ; and
bonding a second component concentrically within the first component.

Assignees

• United Technologies Corp

Inventors

• Shah Dilip M
• Genereux Paul D
• Cetel Alan D
• Marcin Jr John J
• Bullied Steven J
• Bochiechio Mario P
• Schlichting Kevin W
• Cowles Bradford A
• Verner Carl R
• Furrer David U
• Seetharaman Venkatarama K

Classifications

• C30B29/607

  Chemistry & Metallurgy · mapped topic

• F23R2900/00018

  Manufacturing combustion chamber liners or subparts · CPC title

• F01D25/24

  Casings (modified for heating or cooling F01D25/14); Casing parts, e.g. diaphragms, casing fastenings (casings for rotary machines or engines in general F16M {; special arrangements in stators dealing with breaking-off of part of rotor F01D21/045}) · CPC title

• F05D2240/35

  Combustors or associated equipment · CPC title

• F05D2230/211

  by precision casting, e.g. microfusing or investment casting · CPC title