Castings and Manufacture Methods

Patent metadata

Field	Value
Publication number	US-2022088674-A1
Application number	US-202117542840-A
Country	US
Kind code	A1
Filing date	Dec 6, 2021
Priority date	Jun 3, 2013
Publication date	Mar 24, 2022
Grant date	—

Abstract

A method includes casting a metallic material (56) in a mold (20) containing a core, the core having a substrate (40, 44) coated with a coating (42). A removing of the metallic material from the mold and decoring leaves a casting having a layer formed by the coating. The coating has a ceramic having a porosity in a zone (50) near the substrate less than a porosity in a zone (52) away from the substrate.

First claim

1 . A coated casting comprising:
a metallic casting having an airfoil and one or more internal passageways extending through the airfoil; and a ceramic lining along the passageways,
wherein:
the ceramic lining has a porosity in a zone near the casting greater than a porosity in a zone away from the casting.

2 . The coated casting of claim 1 wherein:
the metallic casting at least partially fills the porosity of at least the zone near the casting.

3 . The coated casting of claim 2 wherein:
the zone near the casting comprises a first portion near the casting and a second portion between the first portion and the zone away from the casting, the second portion being less porous than the first portion.

4 . The coated casting of claim 1 wherein:
the metallic casting is a nickel-based superalloy

5 . The coated casting of claim 1 wherein:
the coated casting forms a gas turbine engine component.

6 . The coated casting of claim 1 wherein:
the coated casting has a thermal barrier coating on an exterior surface of differing composition from said coating.

7 . The coated casting of claim 1 wherein:
the casting forms a blade having an attachment root.

8 . The coated casting of claim 1 wherein:
the zone away from the casting is silica-based; and
the zone near the casting is alumina-based.

9 . The coated casting of claim 1 wherein:
the ceramic lining has a characteristic thickness of 1.0 to 10 mil.

10 . The coated casting of claim 1 wherein:
the coating ceramic has a characteristic thickness of 1.0 to 10 mil.

11 . A method for manufacturing the coated casting of claim 1 , the method comprising:
casting a metallic material in a mold containing a core, the core having a substrate coated with a coating; and removing the metallic material from the mold and decoring to leave the metallic casting formed by the metallic material and the ceramic lining formed by the ceramic coating.

12 . The method of claim 11 wherein:
the substrate comprises a molded first ceramic and the coating ceramic comprises a second ceramic different from the first ceramic.

13 . The method of claim 12 further comprising:
applying the second ceramic to the first ceramic by PVD.

14 . The method of claim 11 wherein:
the coating comprises a first layer applied by a first technique and a second layer applied by a second technique, different from the first technique.

15 . The method of claim 14 wherein:
the first technique is a vapor deposition and the second technique is a sol-gel process.

16 . The method of claim 15 wherein:
the second layer comprises a first sublayer and a second sublayer of differing porosities.

17 . (canceled)

18 . The method of claim 11 wherein:
the coating further comprises a second metallic material atop and/or intermixed with the ceramic.

19 . The method of claim 18 wherein:
at least a majority by weight of the second metallic material diffuses into the metallic material.

20 . The method of claim 11 further comprising:
applying a coating to an exterior of the casting, but not the interior.

21 . The method of claim 11 further comprising:
applying a metallic bondcoat to an exterior of the casting by spray and/or PVD; and
applying a ceramic thermal barrier coating to an exterior of the casting by spray and/or PVD.

Assignees

• Raytheon Tech Corp

Inventors

• Prete Thomas W
• Marcin Jr John J
• Beers Russell A

Classifications

• C23C28/321

  with at least one metal alloy layer · CPC title

• Y10T428/1317

  Multilayer [continuous layer] · CPC title

• B22D19/00 Primary

  Casting in, on, or around objects which form part of the product (B22D23/04 takes precedence; alumino-thermic welding B23K23/00; coating by casting molten material on the substrate C23C6/00) · CPC title

• F05D2300/175

  Superalloys · CPC title

• C23C28/044

  coatings specially adapted for cutting tools or wear applications · CPC title