Single crystal parts using additive manufacturing and remelt

Patent metadata

Field	Value
Publication number	US-2016319677-A1
Application number	US-201615211913-A
Country	US
Kind code	A1
Filing date	Jul 15, 2016
Priority date	Apr 19, 2013
Publication date	Nov 3, 2016
Grant date	—

Abstract

A metal single crystal turbine component with internal passageways includes a polycrystalline turbine blade formed by additive manufacturing. The turbine component is remelted and directionally solidified to form the single crystal turbine component with internal passageways.

First claim

1 . A metal single crystal turbine component with internal passageways formed without the use of a wax pattern comprising:
a metal turbine component with internal passageways formed by an additive manufacturing process, that is remelted and directionally solidified to form a metal single crystal turbine component.

2 . The turbine component of claim 1 , wherein the internal passageways are filled with core ceramic before remelting.

3 . The turbine component of claim 1 , wherein the turbine component and ceramic core are encased in a shell mold before remelting.

4 . The turbine component of claim 3 , wherein the core ceramic material is selected from the group consisting of silica, alumina, zircon, cobalt, mullite, and kaolin, and mixtures thereof.

5 . The turbine component of claim 3 , wherein the shell mold ceramic material is selected from the group consisting of silica, alumina, zircon, cobalt, mullite, and kaolin.

6 . The turbine component of claim 1 , wherein the additive manufacturing process comprises at least one of selective laser sintering, selective laser melting, direct metal deposition, direct metal laser melting, and electron beam melting.

7 . The turbine component of claim 1 , wherein the metal is selected from the group consisting of a nickel based superalloy, a cobalt based superalloy, an iron based superalloy, and mixtures thereof.

8 . The turbine component of claim 1 , wherein the metal turbine component is attached to a starter seed or grain selector before remelting.

9 . The turbine component of claim 3 , wherein the shell mold is fired between temperatures of about 1200° F. (649° C.) and about 1800° F. (982° C.) for times between about 10 and about 120 minutes.

Assignees

• United Technologies Corp

Inventors

• Mcbrien John
• Castle Lea Kennard
• Spangler Brandon W

Classifications

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• F01D5/28 Primary

  Selecting particular materials; {Particular measures relating thereto;} Measures against erosion or corrosion · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22C7/02 Primary

  Lost patterns · CPC title

• B22C9/043

  Removing the consumable pattern · CPC title