Multi-component assembly casting
First Claim
1. A vane segment comprising;
- an airfoil comprising an airfoil structural material; and
a shroud segment comprising a shroud heat resistant material and a cast shroud structural material underlying and providing structural support for the shroud heat resistant material, wherein the shroud heat resistant material is discrete from the airfoil structural material, wherein the shroud heat resistant material is set apart from the shroud structural material by not more than a layer of oxides therebetween, wherein the shroud structural material is discrete from, cast around, and secured to an end of the airfoil structural material and acts as a monolithic interlock between the airfoil structural material and the shroud heat resistant material, and wherein a joint between the shroud structural material and the airfoil structural material is free of metallurgical bonds.
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Accused Products
Abstract
Multi-component vane segment and method for forming the same. Assembly includes: positioning a pre-formed airfoil component (12) and a preformed shroud heat resistant material (18) in a mold, wherein the airfoil component (12) and the shroud heat resistant material (18) each comprises an interlocking feature (24); preheating the mold; introducing molten structural material (46) into the mold; and solidifying the molten structural material such that it interlocks the pre-formed airfoil component (12) with respect to the preformed shroud heat resistant material (18) and is effective to provide structural support for the shroud heat resistant material (18). Surfaces between the airfoil component (12) and the structural material (46), between the airfoil component (12) and the shroud heat resistant material (18), and between the shroud heat resistant material (18) and the structural material (46) are free of metallurgical bonds.
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Citations
27 Claims
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1. A vane segment comprising;
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an airfoil comprising an airfoil structural material; and a shroud segment comprising a shroud heat resistant material and a cast shroud structural material underlying and providing structural support for the shroud heat resistant material, wherein the shroud heat resistant material is discrete from the airfoil structural material, wherein the shroud heat resistant material is set apart from the shroud structural material by not more than a layer of oxides therebetween, wherein the shroud structural material is discrete from, cast around, and secured to an end of the airfoil structural material and acts as a monolithic interlock between the airfoil structural material and the shroud heat resistant material, and wherein a joint between the shroud structural material and the airfoil structural material is free of metallurgical bonds. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A vane segment comprising;
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an airfoil; and a shroud segment comprising a shroud heat resistant material and a cast shroud structural material underlying and providing structural support for the shroud heat resistant material, wherein the shroud heat resistant material is discrete from the airfoil, and wherein the shroud heat resistant material is separated from the shroud structural layer by not more than a layer of oxides therebetween, wherein a joint between the shroud heat resistant material and the airfoil is free of metallurgical bonds, wherein the shroud structural material acts as a monolithic interlock between the shroud heat resistant material and the airfoil. - View Dependent Claims (14, 15)
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16. A method for forming a vane segment comprising:
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positioning a pre-formed airfoil component and a preformed shroud heat resistant material in a mold, wherein the airfoil component and the shroud heat resistant material are discrete from each other and wherein each comprises an interlocking feature; preheating the mold; introducing molten structural material into the mold; and solidifying the molten structural material around an end of the pre-formed airfoil component to form a monolithic body that interlocks the pre-formed airfoil component with respect to the preformed shroud heat resistant material and is effective to provide structural support for the shroud heat resistant material, and wherein surfaces between the airfoil component and the cast structural material, between the airfoil component and the shroud heat resistant material, and between the shroud heat resistant material and the cast structural material are free of metallurgical bonds and separated from each other by not more than a layer of oxides therebetween. - View Dependent Claims (17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27)
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Specification