Method of manufacturing rotor such as impeller or turbine wheel

Abstract

Disclosed is a method of manufacturing an impeller or a turbine wheel having a disk hub and an air foil. The method includes forming a mold for casting including a cavity of a shape corresponding to the rotor, arranging a core at a location corresponding to an inside of the rotor in the cavity of the mold for casting, injecting molten metal into the mold for casting where the core has been arranged, and removing the core from a casting which has been cast in the mold for casting.

What is claimed is: 
     
         1 . A method of manufacturing a rotor, the method comprising:
 forming a mold for casting including a cavity of a shape corresponding to the rotor; arranging a core at a location corresponding to an inside of the rotor in the cavity of the mold for casting; injecting molten metal into the mold for casting where the core has been arranged; and removing the core from a casting which has been cast in the mold for casting.   
     
     
         2 . The method of  claim 1 , wherein the core is arranged to revolve around a rotation axis of the impeller or the turbine wheel in the inside of the rotor. 
     
     
         3 . The method of  claim 1 , wherein the core is a material comprising ceramic, and
 wherein the core is removed by a ceramic leaching process when removing the core from the casting.   
     
     
         4 . The method of  claim 1 , wherein the forming the mold for casting comprises coating a model of the shape corresponding to the rotor, and
 wherein the core has been injected into the model in advance when arranging the core in the cavity of the mold for casting.   
     
     
         5 . The method of  claim 4 , wherein the model comprises wax. 
     
     
         6 . The method of  claim 4 , wherein the coating comprises slurry-coating. 
     
     
         7 . The method of  claim 4 , wherein the core is arranged to revolve around a rotation axis of the rotor in the inside of the rotor. 
     
     
         8 . The method of  claim 4 , wherein the core is a material comprising ceramic, and
 wherein the core is removed by a ceramic leaching process when removing the core from the casting.   
     
     
         9 . The method of  claim 4 , further comprising:
 preparing a modeling mold having a cavity of the shape corresponding to the rotor;   arranging the core in an inside of the cavity of the modeling mold;   injecting a model material into the inside of the cavity of the modeling mold where the core has been arranged, and solidifying the model material; and   extracting the model solidified in the modeling mold so that the core is injected into the model in advance.   
     
     
         10 . The method of  claim 9 , wherein the core is arranged to revolve around a rotation axis of the rotor in the inside of the rotor. 
     
     
         11 . The method of  claim 10 , wherein the core comprises ceramic, and
 wherein the core is removed by a ceramic leaching process when removing the core from the casting.   
     
     
         12 . The method of  claim 9 , wherein the core is a material comprising ceramic, and
 wherein the core is removed by a ceramic leaching process when removing the core from the casting.   
     
     
         13 . The method of  claim 9 , wherein the model material comprises wax. 
     
     
         14 . The method of  claim 1  further comprising extracting the casting by removing the mold for casting. 
     
     
         15 . The method of  claim 14 , wherein the removing the mold for casting and the removing the core from the casing are performed simultaneously. 
     
     
         16 . The method of  claim 14 , wherein the removing the mold for casting is performed before the removing the core from the casting. 
     
     
         17 . The method of  claim 14 , wherein the removing the mold for casting is performed after the removing the core from the casting. 
     
     
         18 . The method of  claim 1 , further comprising forming a cavity inside the casting by the removing the core from the casting. 
     
     
         19 . The method of  claim 1 , wherein the rotor is an impeller or a turbine wheel.