Multi-walled airfoil core

Patent metadata

Field	Value
Publication number	US-11434768-B2
Application number	US-202117322211-A
Country	US
Kind code	B2
Filing date	May 17, 2021
Priority date	Oct 1, 2018
Publication date	Sep 6, 2022
Grant date	Sep 6, 2022

Abstract

An airfoil core includes a first core portion that has a hybrid skin core, a tip flag core, and a trailing edge core. A second core portion has a serpentine core and a leading edge core.

First claim

The invention claimed is:

1. An airfoil core, comprising:
a first core portion having a hybrid skin core, a tip flag core, and a trailing edge core distributed in a chordwise direction between a leading edge of the airfoil core and a trailing edge of the airfoil core, wherein the trailing edge core is adjacent to a trailing edge of the airfoil core, the hybrid skin core and the trailing edge core extend in a spanwise direction, the tip flag core extends in the chordwise direction along a tip of the airfoil core from the hybrid skin core to the trailing edge of the airfoil core, the tip flag core extends in a thickness direction between a pressure side and a suction side of the airfoil core, and the hybrid skin core is arranged along the suction side of the airfoil core; and
a second core portion having a serpentine core and a leading edge core distributed in the chordwise direction, wherein the leading edge core is adjacent to the leading edge of the airfoil core such that the leading edge core and the hybrid skin core are aligned in the chordwise direction, and the serpentine core is arranged along the pressure side of the airfoil core.

2. The airfoil core of claim 1 , wherein the hybrid skin core, the tip flag core and the trailing edge core are injection molded as a single structure.

3. The airfoil core of claim 1 , wherein the serpentine core and the leading edge core are injection molded as a second single structure.

4. The airfoil core of claim 1 , wherein a rod connects the serpentine core and the tip flag core.

5. The airfoil core of claim 1 , wherein the hybrid skin core and the trailing edge core are connected at an inlet.

6. The airfoil core of claim 1 , wherein a rod connects the trailing edge core and the tip flag core.

7. The airfoil core of claim 1 , wherein the trailing edge core and the tip flag core are connected via core material along the trailing edge of the airfoil core.

8. The airfoil core of claim 1 , wherein a rod extends from the leading edge core to a feature radially outward of the tip flag core.

9. The airfoil core of claim 8 , wherein a second rod extends radially outward of the serpentine core to the feature.

10. The airfoil core of claim 1 , wherein the airfoil core has a plurality of heat transfer augmentation features.

11. The airfoil core of claim 1 , wherein the serpentine core is arranged inward of the tip flag core relative to the spanwise direction.

12. The airfoil core of claim 1 , wherein the leading edge core is configured to form a plurality of cavities spaced radially along a leading edge.

13. The airfoil core of claim 1 , wherein:
the serpentine core includes first, second and third serpentine sections distributed in the chordwise direction to establish a serpentine geometry, wherein each of the first, second and third serpentine sections extends in the spanwise direction, and wherein the second serpentine section interconnects the first and third serpentine sections at respective bends at opposite ends of the second serpentine section; and
the tip flag core includes first and second flag portions, the first flag portion extends in the chordwise direction from the hybrid skin core at the tip of the airfoil core, the second flag portion extends in the chordwise direction from the first flag portion to the trailing edge of the airfoil core, the first flag portion and the second serpentine section are aligned in the thickness direction between the pressure and suction sides, the second flag portion and the third serpentine section are aligned in the chordwise direction, and the second flag portion extends in the thickness direction between the pressure and suction sides such that the second flag portion is between the third serpentine section and the tip of the airfoil core relative to the spanwise direction.

14. The airfoil core of claim 13 , wherein the serpentine core is arranged in the chordwise direction between the leading edge core and the trailing edge core.

15. The airfoil core of claim 14 , wherein the first flag portion flares outwardly in the thickness direction from the hybrid skin core to the second flag portion to establish the pressure side of the airfoil core.

16. The airfoil core of claim 15 , wherein the second serpentine section and the first flag portion are aligned in the chordwise direction.

17. The airfoil core of claim 16 , wherein the leading edge core and the first serpentine section are spaced apart from each other in the chordwise direction.

18. The airfoil core of claim 17 , wherein:
the hybrid skin core includes a first column of slots and a second column of slots extending in the spanwise direction, and wherein the first column of slots are spaced apart from the second column of slots with respect to the chordwise direction; and
the first column of slots includes a first slot, the second column of slots includes a second slot, and the first and second slots are aligned in the spanwise direction with the tip flag core.

19. The airfoil core of claim 18 , wherein:
an inlet portion of the hybrid skin core and an inlet portion of the trailing edge core are joined together at a position inward of the first and second columns of slots relative to the spanwise direction to establish the first core portion; and
an inlet portion of the serpentine core and an inlet portion of the lead edge core are joined together at a position inward of the respective bends of the serpentine core relative to the spanwise direction to establish the second core portion.

20. The airfoil core of claim 16 , wherein the first serpentine section extends in the spanwise direction to the tip of the airfoil core such that the first serpentine section is arranged in the chordwise direction between the leading edge core and the first flag portion.

Assignees

• Raytheon Tech Corp

Inventors

• Peters Christopher J
• Place Emma J
• Degray Jeffrey J
• Mongillo Dominic J
• Jennings Timothy J
• Surace Raymond
• Fredette Jeremy B

Classifications

• B22C9/103

  Multipart cores · CPC title

• B22C9/046

  Use of patterns which are eliminated by the liquid metal in the mould · CPC title

• B22D25/02

  by its peculiarity of shape; of works of art {(cylinders, pistons B22D15/02)} · CPC title

• F05D2230/211

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

• F01D5/189 Primary

  the insert having a tubular cross-section, e.g. airfoil shape · CPC title