Method for forming components using additive manufacturing and re-melt

Patent metadata

Field	Value
Publication number	US-10570744-B2
Application number	US-201615228543-A
Country	US
Kind code	B2
Filing date	Aug 4, 2016
Priority date	May 9, 2014
Publication date	Feb 25, 2020
Grant date	Feb 25, 2020

Abstract

A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified.

First claim

What is claimed is:

1. A method of manufacturing a component, comprising:
additively manufacturing a crucible for casting of the component, wherein the crucible includes a core and a shell;
adding metal material in powder form to the crucible, wherein the metal material is a superalloy;
solidifying the metal material within the crucible to form a metal directionally solidified microstructure within the component; and
removing the crucible to reveal the component;
wherein the method further comprises:
manufacturing the core and the shell of a material that is different from the metal material;
additively manufacturing internal cooling passages of the component using a ceramic material;
additively manufacturing locations for microcircuits of the component using a refractory metal material, wherein the microcircuits are smaller than and located outboard of the internal cooling passages;
filling the internal cooling passages with a ceramic slurry to form the core; and
curing the core.

2. The method as recited in claim 1 , further comprising:
forming the shell over the component and the core by dipping the component into a ceramic powder and binder slurry to form a layer of ceramic material covering the component.

Assignees

• United Technologies Corp

Inventors

• Xu Jinquan

Classifications

• B22C9/12

  Treating moulds or cores, e.g. drying, hardening · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B22C9/04

  Use of lost patterns · CPC title

• B22F5/007

  of moulds · CPC title