Chromalloy Gas Turbine Corporation

Gerald Clement Dodds

Thomas John Molkentin

Zachary Oras

Zachary E Baierl

Mark S Haber

A system for producing a core including a core profile for use in casting. The system comprises a cavity block including an upper portion, a lower portion, and a recessed cavity in each of the upper portion and the lower portion; an adapter insert including a first portion and a second portion, the adapter insert sized to fit within the recessed cavity in each of the upper portion and the lower portion of the cavity block; and a core die insert sized to fit and be positioned within the adapter insert. The core die insert includes a sacrificial material and a hollow internal profile, with the hollow profile of the core die insert corresponding to the core profile.

Method and apparatus for improving core manufacturing for gas turbine components

A single crystal ceramic core composition has an inorganic portion and an organic portion. The inorganic portion makes up about 85% by weight of the total weight of the ceramic core composition, and the organic portion makes up about 15% by weight of the total weight of the ceramic core composition. The inorganic portion includes about 94 to 98% by weight spherical fused silica, and about 2 to 6% by weight zircon flour. The organic portion includes about 84 to 88% by weight binder, about 1 to 2% by weight dye, about 6 to 12% by weight surfactant, and about 1 to 5% by weight polymeric fiber.

Spherical fused silica compositions for injection molded ceramic cores and methods of making parts using such compositions

An apparatus and method for producing a core for use in casting a gas turbine component is provided. The apparatus comprises a system having a cavity block with an upper portion, a lower portion, and a recessed cavity in each of the upper portion and the lower portion. Positioned within the cavity block is an adapter insert, and within the adapter insert is positioned a core die insert, where the core die insert is fabricated from a sacrificial material and has a hollow internal profile corresponding to an external surface of a core. A ceramic-based material is supplied to the core die insert where it solidifies. The core die insert is placed into a water-based solution and the core die insert is removed from around the core.

A tool for reforming a core pattern. A method of reforming a core pattern comprises opening a core reformer tool. The core reformer tool has a first portion and a second portion facing the first portion. The first portion includes a concave member and a first adjustable pin. The second portion includes a convex member and a second adjustable pin. The method includes positioning the core pattern in the core reformer tool and closing the core reformer tool. The method comprises adjusting at least one of the first adjustable pin and the second adjustable pin to alter a surface of the core pattern. The method includes directing cooling air through the core reformer tool to solidify the core pattern and opening the core reformer tool to remove the core pattern.

Core pattern reformer tool

A core pattern reformer system for adjusting and setting a core pattern for use in casting a gas turbine blade has a first portion having a first internal face with a concave portion. The first portion is coupled to a second portion. The second portion has a second internal face with a convex portion. A plurality of adjustable pins is positioned along the internal faces of the first portion and the second portion. The pins have a height that is adjustable with respect to the internal faces. A locking mechanism is included for securing the first portion to the second portion. The system includes one or more air inlets and one or more air exits and a source of cooling air coupled to the one or more air inlets.

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Lutz, FL, United States of America

Gerald Clement Dodds