Additively manufactured core

Patent metadata

Field	Value
Publication number	US-2016151829-A1
Application number	US-201414904991-A
Country	US
Kind code	A1
Filing date	Jul 2, 2014
Priority date	Jul 19, 2013
Publication date	Jun 2, 2016
Grant date	—

Abstract

A method of preparing a casting article for use in manufacturing a gas turbine engine part according to an exemplary aspect of the present disclosure includes, among other things, communicating a powdered material to an additive manufacturing system and preparing a casting article that includes at least one trunk and a skin core that extends from the at least one trunk out of the powdered material.

First claim

What is claimed is:

1 . A method of preparing a casting article for use in manufacturing a gas turbine engine part, comprising the steps of:
communicating a powdered material to an additive manufacturing system; and preparing a casting article that includes at least one trunk and a skin core that extends from the at least one trunk out of the powdered material.

2 . The method as recited in claim 1 , wherein the powdered material includes a refractory metal.

3 . The method as recited in claim 1 , wherein the powdered material includes a ceramic, silica or alumina.

4 . The method as recited in claim 1 , wherein the powdered material includes at least two of a refractory metal, a ceramic, a silica and an alumina.

5 . The method as recited in claim 1 , wherein the step of communicating includes:
positioning the powdered material on a delivery platform; moving the delivery platform relative to a build platform; and depositing a layer of the powdered material onto the build platform.

6 . The method as recited in claim 1 , wherein the step of preparing includes:
melting a first layer of the powdered material to form a first cross-sectional layer of the casting article; spreading a second layer of the powdered material on top of the first cross-sectional layer; and melting the second layer to form a second cross-sectional layer of the casting article.

7 . The method as recited in claim 6 , wherein the first cross-sectional layer and the second cross-sectional layer are formed with reference to CAD data communicated to the additive manufacturing system.

8 . The method as recited in claim 1 , wherein the at least one trunk includes a solid core geometry.

9 . The method as recited in claim 1 , wherein the at least one trunk includes a hollow outer shell body at least partially filled with the powdered material.

10 . The method as recited in claim 1 , wherein the at least one trunk includes an internal matrix formed inside of an outer shell body.

11 . The method as recited in claim 1 , wherein at least one of the at least one trunk and the skin core includes a vascular network.

12 . The method as recited in claim 1 , wherein the step of preparing includes integrally building the at least one trunk and the skin core with the additive manufacturing system.

13 . A method of preparing a core for use in casting a gas turbine engine part, comprising the steps of:
depositing multiple layers of a powdered material onto one another using an additive manufacturing system; joining the layers to one another with reference to CAD data relating to a particular cross-section of a desired core geometry of a core; and producing a core having the core geometry which includes at least a trunk that forms a mainbody cooling passage of a cast gas turbine engine part and a skin core that forms an internal cooling feature of the cast gas turbine engine part.

14 . The method as recited in claim 13 , wherein the powdered metal includes at least one of a refractory metal, a silica and an alumina.

15 . The method as recited in claim 13 , wherein the step of joining includes:
melting at least a portion of a second layer of the powdered material to adhere the second layer to a first layer.

16 . The method as recited in claim 13 , wherein a portion of the core geometry is at least partially filled with the powdered metal.

17 . The method as recited in claim 13 , wherein the core geometry includes an internal matrix formed inside of the trunk.

18 . The method as recited in claim 13 , wherein at least a portion of the core geometry includes a vascular network.

19 . The method as recited in claim 13 , wherein the step of preparing includes integrally building the at least one trunk and the skin core with the additive manufacturing system.

20 . A casting article, comprising:
a trunk; a skin core that extends from said trunk; and at least one of said trunk and said skin core including a portion that embodies a vascular network.

Assignees

• United Technologies Corp

Inventors

• Propheter-Hinckley Tracy A
• Mongillo Jr Dominic J
• Fisk Benjamin T

Classifications

• B22F3/24

  After-treatment of workpieces or articles {(B22F3/1146 takes precedence)} · CPC title

• F01D5/284

  Selection of ceramic materials · CPC title

• B22F2003/244

  Leaching · CPC title

• B22F5/009

  of turbine components other than turbine blades (of turbine blades B22F5/04) · CPC title

• F05D2230/22

  by sintering · CPC title