Method and assembly for forming components having internal passages using a lattice structure

Patent metadata

Field	Value
Publication number	US-9975176-B2
Application number	US-201715410295-A
Country	US
Kind code	B2
Filing date	Jan 19, 2017
Priority date	Dec 17, 2015
Publication date	May 22, 2018
Grant date	May 22, 2018

Abstract

A method of forming a component having an internal passage defined therein includes selectively positioning a lattice structure at least partially within a cavity of a mold. The lattice structure is formed from a first material, and a core is positioned in a channel defined through the lattice structure, such that at least a portion of the core extends within the cavity. The method also includes introducing a component material in a molten state into the cavity, such that the component material in the molten state at least partially absorbs the first material from the lattice structure. The method further includes cooling the component material in the cavity to form the component, wherein at least the portion of the core defines the internal passage within the component.

First claim

What is claimed is:

1. A method of forming a component having an internal passage defined therein, said method comprising:
inserting a preformed core through a channel defined through a lattice structure;
selectively positioning the lattice structure at least partially within a cavity of a mold, wherein at least a portion of the inserted core extends within the mold cavity;
introducing a component material in a molten state into the cavity, such that the component material in the molten state at least partially absorbs the lattice structure; and
cooling the component material in the cavity to form the component, wherein at least the portion of the core defines the internal passage within the component.

2. The method of claim 1 , wherein said introducing the component material in the molten state into the mold cavity comprises introducing the component material such that a performance of the component material in a solid state is not degraded by the at least partial absorption of the first material.

3. The method of claim 1 , wherein said introducing the component material in the molten state into the mold cavity comprises introducing an alloy in a molten state into the mold cavity, wherein the first material comprises at least one constituent material of the alloy.

4. The method of claim 1 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure formed from the first material that includes at least one of nickel, cobalt, iron, and titanium.

5. The method of claim 1 , wherein the mold includes an interior wall that defines the cavity and the lattice structure defines a perimeter, said selectively positioning the lattice structure comprises coupling the perimeter of the lattice structure against the interior wall of the mold.

6. The method of claim 1 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that includes a plurality of elongated members that define a plurality of open spaces therebetween.

7. The method of claim 6 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that includes the plurality of open spaces arranged such that each region of the lattice structure is in flow communication with substantially each other region of the lattice structure.

8. The method of claim 6 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that includes at least one group of sectional elongated members of the plurality of elongated members, each at least one group is shaped to be positioned within a corresponding cross-section of the mold cavity.

9. The method of claim 8 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that includes at least one stringer elongated member of the plurality of elongated members that extends between at least two of the groups.

10. The method of claim 1 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure configured to at least partially support a weight of the core during at least one of pattern forming, shelling of the mold, and/or component forming.

11. The method of claim 1 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that includes the channel defined through the lattice structure by a series of openings in the lattice structure that are aligned to receive the core.

12. The method of claim 1 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that includes the channel defined by a hollow structure that encloses the core.

13. The method of claim 12 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that defines a perimeter shaped for insertion into the mold cavity through an open end of the mold, such that the lattice structure and the hollow structure define an insertable cartridge.

14. A method of forming a component having an internal passage defined therein, said method comprising:
selectively positioning a lattice structure at least partially within a cavity of a mold, wherein a hollow structure is coupled to the lattice structure and defines a channel therethrough, the hollow structure enclosing a core along a length of the core, such that at least a portion of the core extends within the cavity;
introducing a component material in a molten state into the cavity, such that the component material in the molten state at least partially absorbs the lattice structure; and
cooling the component material in the cavity to form the component, wherein at least the portion of the core defines the internal passage within the component.

15. The method of claim 14 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that includes a plurality of elongated members that define a plurality of open spaces therebetween.

16. The method of claim 15 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that includes the plurality of open spaces arranged such that each region of the lattice structure is in flow communication with substantially each other region of the lattice structure.

17. The method of claim 14 , wherein said selectively positioning the lattice structure comprises selectively positioning the lattice structure that defines a perimeter shaped for insertion into the mold cavity through an open end of the mold, such that the lattice structure and the hollow structure define an insertable cartridge.

Assignees

• Gen Electric

Inventors

• Rutkowski Stephen Francis

Classifications

• B22D30/00

  Cooling castings, not restricted to casting processes covered by a single main group (accessories for cooling cast stock in continuous casting of metals B22D11/124; controlling or regulating processes or operations for cooling cast stock or mould in continuous casting of metals B22D11/22; chill casting B22D15/00) · CPC title

• F01D5/18

  Hollow blades, {i.e. blades with cooling or heating channels or cavities (structure of hollow blades in general F01D5/147)}; Heating, heat-insulating or cooling means on blades · CPC title

• B22D25/02 Primary

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

• B22C7/00

  Patterns; Manufacture thereof so far as not provided for in other classes · CPC title

• B22D19/02

  for making reinforced articles (B22D19/14 takes precedence) · CPC title