COMPOSITE TOOL AND METHOD FOR FORMING COMPOSITE COMPONENTS

• US 20160214283A1
• Filed: 01/26/2015
• Published: 07/28/2016
• Est. Priority Date: 01/26/2015
• Status: Abandoned Application

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: HAFNER, Matthew Troy, BARNELL, Steven, SCHICK, David Edward, PAROLINI, Jason Robert
• Application Number:
  US14/604,910
• Publication Number:
  US 20160214283A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 33/56 Coatings , e.g. enameled or galvanised; Releasing, lubricating or separating agents in-mould coating B29C37/0028; using or applying separating agents B29C37/0067
• CPC Class Codes: B29C 33/76 Cores B29C33/02 - B29C33/70, B29C41/40, B29C53/74, B29C53/82 take precedence
• CPC Class Codes: B29C 70/44 using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
• CPC Class Codes: B29C 70/70 Completely encapsulating inserts B29C70/86 takes precedence
• CPC Class Codes: B29C 70/865 completely encapsulated
• CPC Class Codes: B29K 2105/0872 Prepregs
• CPC Class Codes: B29K 2901/12 Thermoplastic materials
• CPC Class Codes: B29K 2905/08 Transition metals
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: F01D 5/282 Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F05D 2220/30 in turbines
• CPC Class Codes: F05D 2230/40 Heat treatment
• CPC Class Codes: F05D 2230/90 Coating; Surface treatment
• CPC Class Codes: F05D 2250/20 Three-dimensional
• CPC Class Codes: F05D 2300/43 Synthetic polymers, e.g. plastics; Rubber
• CPC Class Codes: Y02T 50/60 Efficient propulsion technologies, e.g. for aircraft

Abstract

Provided are a composite tool and a method for forming composite components. The composite tool includes a three dimensionally printed polymer body, the body having a geometry corresponding to at least one surface of a gas turbine component; and a coating overlaying the body, the coating providing the printed polymer body a greater resistance to heat exposure than an uncoated printed polymer body. The method for forming a composite component includes providing a composite tool; laying-up a plurality of composite plies on a surface of the composite tool; densifying the composite plies to form a composite component; and removing the composite tool from the composite component. The composite component includes a surface geometry corresponding to at least a portion of the composite tool. Also provided is a method of forming the composite tool.

Claims

1. A composite tool comprising:

a three dimensionally printed polymer body, the body having a geometry corresponding to at least one surface of a gas turbine component; and

a coating overlaying the body, the coating providing the printed polymer body a greater resistance to heat exposure than an uncoated printed polymer body.

2. The composite tool of claim 1, wherein the greater resistance to heat exposure includes survival of exposure to a temperature greater than the glass transition temperature of the three dimensionally printed polymer body.

3. The composite tool of claim 1, wherein the composite tool is a mandrel.

4. The composite tool of claim 1, wherein the three dimensionally printed body includes a plurality of segments.

5. The composite tool of claim 4, wherein the plurality of segments include segments that are attachable to one another to form the geometry corresponding to at least one surface of a gas turbine component.

6. The composite tool of claim 1, wherein the coating comprises a material selected from copper, nickel, and combinations thereof.

7. The composite tool of claim 1, wherein the gas turbine component is one of a turbine blade or shroud.

8. A method of forming a composite tool comprising:

printing a three dimensional polymer body, the body having a geometry corresponding to at least one surface of a gas turbine component; and

applying a coating to the polymer body, the coating providing the printed polymer body a greater resistance to heat exposure than an uncoated printed polymer body.

9. The method of claim 8, wherein the greater resistance to heat exposure includes survival of exposure to a temperature greater than the glass transition temperature of the three dimensionally printed polymer body.

10. The method of claim 8, wherein the greater resistance to heat exposure includes survival of one or more autoclave burnout cycles.

11. The method of claim 8, wherein the three dimensionally printed body includes a plurality of segments.

12. The method of claim 11, wherein the plurality of segments include segments that are attachable to one other to form the geometry corresponding to at least one surface of a gas turbine component.

13. The method of claim 8, wherein the coating comprises a material selected from copper, nickel, and combinations thereof.

14. The method of claim 8, wherein the gas turbine component is one of a turbine blade or shroud.

15. The method of claim 8, wherein the composite tool is a mandrel.

16. A method of forming a composite component comprising:

providing a composite tool comprising;

a three dimensionally printed polymer body; and

a coating overlaying the body, the coating providing the printed polymer body a greater resistance to heat exposure than an uncoated printed polymer body;

laying-up a plurality of composite plies on a surface of the composite tool;

densifying the composite plies to form a composite component; and

removing the composite tool from the composite component;

wherein the composite component includes a surface geometry corresponding to at least a portion of the composite tool.

17. The method of claim 16, wherein the densifying includes heating to a temperature equal to or greater than the glass transition temperature of the three dimensionally printed polymer body.

18. The method of claim 16, wherein the densifying includes heating to a temperature of equal to or greater than 350°

F.

19. The method of claim 16, wherein the coating comprises a material selected from copper, nickel, and combinations thereof.

20. The method of claim 16, wherein the gas turbine component is one of a turbine blade or shroud.