Method for forming turbine blade with angled internal ribs

• US 20060292005A1
• Filed: 06/23/2005
• Published: 12/28/2006
• Est. Priority Date: 06/23/2005
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Rtx Corporation)
• Inventors: Downs, James P., Singer, Irwin D., Pietraszkiewicz, Edward
• Granted Patent: US 7,569,172 B2
• Time in Patent Office: Days
• US Class Current: 416/97.00R
• CPC Class Codes: B22C 7/06 Core boxes
• CPC Class Codes: B22C 9/10 Cores; Manufacture or installation of cores breaker cores B22C9/084
• CPC Class Codes: F01D 5/187 Convection cooling
• CPC Class Codes: F05D 2230/21 by casting
• CPC Class Codes: F05D 2230/50 Building or constructing in particular ways

Abstract

A die for forming a lost wax ceramic core allows the formation of non-parallel separating spaces between adjacent portions of the core. The core will eventually form cooling channels in an airfoil. The die for forming the core includes a plurality of moving parts having rib extensions. At least some rib extensions are non-parallel to form the non-parallel spaces. The die includes two main die halves that come together to form several of the spaces. Inserts move with those die components and come together to form other spaces. At least one of the inserts contacts surfaces on one of the die halves, such that the non-parallel spaces are formed.

Claims

1. A method of forming a ceramic core for forming cooling channels within a turbine component comprising the steps of:

(1) providing a die having a plurality of moving parts, said moving parts having rib extensions,

(2) bringing at least one of said moving parts into contact with at least two other moving parts, said rib extensions forming solid surfaces within a die cavity, and said solid surfaces including at least two solid surfaces which are non-parallel to each other.

(3) injecting a material into said die cavity to form a core.

2. The method as set forth in claim 1, wherein said rib extensions on each of said moving parts are parallel to a direction of movement of the moving part.

3. The method as set forth in claim 1, wherein said moving parts having a plurality of rib extensions.

4. The method as set forth in claim 1, wherein at least some of said rib extensions contacting a surface on another moving part.

5. The method as set forth in claim 4, wherein others of said rib extensions contacting rib extensions on another moving part.

6. The method as set forth in claim 1, wherein said at least two other moving parts moving in non-parallel directions relative to each other.

7. The method as set forth in claim 1, wherein said plurality of moving parts include two die halves, with each of said die halves carrying movable inserts, with said movable inserts on said die halves cooperating to form a trailing edge cooling channel and a leading edge cooling channel.

8. The method as set forth in claim 7, wherein at least one of said movable inserts is said at least one of said moving parts.

9. The method as set forth in claim 8, wherein said at least one of said movable inserts forms a cooling channel at said trailing edge.

10. The method as set forth in claim 1, wherein said turbine component is a turbine blade.

11. The method of claim 1, wherein said core is placed in a lost wax mold and forms cooling channels within a turbine component.

12. A turbine blade comprising:

an airfoil body having a leading edge and a trailing edge, with a plurality of cooling channels being formed within said body;

said cooling channels being separated from adjacent cooling channels by ribs, and a plurality of said cooling channels communicating with each to form a serpentine flow path for cooling fluid; and

ribs defining said serpentine flow path, at least some of said ribs being non-parallel to each other, with at least one rib forming said serpentine flow path being parallel to other ribs spaced toward one of said leading or trailing edges, and outwardly of said serpentine flow path.

13. The turbine blade as set forth in claim 12, wherein said one of said leading and trailing edges is said trailing edge.

14. A die for forming cores for forming a turbine component comprising:

a die having a plurality of moving parts, said moving parts having rib extensions with said rib extensions contacting a portion of another part in said die as said moving parts move together; and

at least one of said moving parts movable into contact with at least two others of said moving parts, said rib extensions for forming solid surfaces within a die cavity, and said solid surfaces including at least a pair of solid surfaces which are non-parallel to each other.

15. The die as set forth in claim 14, wherein said rib extensions on each of said moving parts are parallel to a direction of movement of the moving part.

16. The die as set forth in claim 15, wherein said moving parts having a plurality of rib extensions.

17. The die as set forth in claim 14, wherein at least some of said rib extensions contacting a surface on another moving part.

18. The die as set forth in claim 17, wherein others of said rib extensions contacting rib extensions on another moving part.

19. The die as set forth in claim 14, wherein said at least two others of said moving parts moving in non-parallel directions relative to each other.

20. The die as set forth in claim 14, wherein said plurality of moving parts includes a pair of die halves, with each of said die halves carrying movable inserts for forming a cooling channel at a leading edge and for forming a cooling channel at a trailing edge, and at least one of said inserts being said at least one of said moving parts, and said at least two others of said moving parts including another of said inserts, and one of said die halves.