Cast titanium compressor wheel

• US 6,629,556 B2
• Filed: 05/07/2002
• Issued: 10/07/2003
• Est. Priority Date: 06/06/2001
• Status: Expired due to Term

• Current Assignee: BorgWarner Incorporated
• Original Assignee: BorgWarner Incorporated
• Inventors: Decker, David M., Roby, Steven
• Primary Examiner(s): Lin, Kuang Y.
• Application Number:
  US10/140,746
• Publication Number:
  US 20020185244A1
• Time in Patent Office: 518 Days
• Field of Search: 164/45, 164/34, 164/35, 164/36, 164/516, 164/517, 164/518, 164/519
• US Class Current: 164/35
• CPC Class Codes: B22C 7/02 Lost patterns
• CPC Class Codes: B22C 9/04 Use of lost patterns
• CPC Class Codes: F04D 29/023 especially adapted for elastic fluid pumps
• CPC Class Codes: F04D 29/284 for compressors
• CPC Class Codes: F05D 2230/211 by precision casting, e.g. microfusing or investment casting
• CPC Class Codes: F05D 2300/133 Titanium

Abstract

A compressor wheel is re-designed to permit die inserts (20), which occupy the air passage and define the blades (4, 5) during a process of forming a wax pattern (21) of a compressor wheel, to be pulled without being impeded by the blades. This modified blade design enables the automated production of wax patterns (21) using simplified tooling. These wax patterns (21) can be used in a large-scale investment casting process, and produce an economical cast titanium compressor wheel which performs aerodynamically at high boost pressure/RPM. The compressor wheel improves low cycle fatigue, withstands high temperatures and temperature changes, and permits operation at high boost pressure ratio while, on the other hand, having low weight, low inertial drag, and high responsiveness. The invention further concerns an economical method for operating an internal combustion engine, comprising providing said engine with an easily manufactured, long-life titanium compressor wheel and driving the titanium compressor wheel at high RPM for increasing combustion air throughput and density.

Claims

1. A method for manufacturing a titanium centrifugal compressor wheel, said method comprising:

introducing a sacrificial material into a die comprised of a plurality of rigid die inserts (20) to form a compressor wheel pattern comprising a hub (1) defining an axis of rotation and backswept aerodynamic blades (4, 5) carried on said hub,

extracting said die inserts (20) radially or along a curve to expose said compressor wheel pattern,

forming a mold by a lost wax process around said compressor wheel pattern (21),

forming said titanium compressor wheel by investment casting in said mold.

2. A method as in claim 1, wherein said die insert retraction is by an automated process.

3. A method as in claim 2, wherein said automated process is a hydraulic, pneumatic, or electric process.

4. A method as in claim 1, wherein said die comprises one die insert (20, 20′

) to define each of said air passages between adjacent blades.

5. A method as in claim 1, wherein said aerodynamic blades comprise alternating full blades (4) and splitter blades (5).

6. A method as in claim 1, wherein said titanium compressor wheel is formed of a titanium-aluminum alloy.

7. A method for manufacturing a cast titanium centrifugal compressor wheel comprising:

designing a compressor wheel pattern shape with an annular hub (1) and a plurality of backswept blades (4, 5), each blade including a leading edge (18), an outer edge adapted for close passage to a compressor housing, and a trailing edge (16), wherein said leading edge (18) is substantially a straight edge, and wherein said blades (4, 5) define air passages between adjacent blades and are contoured such that each of said air passages between adjacent blades can be defined by not more than three die inserts (20) inserted between adjacent blades and respectively retractable along a radial or curved path by an automated process,

forming a pattern of said compressor wheel by introducing a sacrificial material into a die comprised of a plurality of rigid die inserts (20),

automatically extracting said rigid die inserts (20) radially or along a curve to expose said compressor wheel pattern,

forming a mold by a lost wax process around said compressor wheel pattern (21),

forming said titanium compressor wheel by investment casting in said mold.

8. A method as in claim 7, wherein said blades comprise full blades and splitter blades.

9. A method as in claim 7, wherein said titanium compressor wheel is formed of a titanium-aluminum alloy.