Method of making surface cooling channels on a component using lithographic molding techniques

Abstract

Methods of casting a component including one or more surface cooling channels. The method including casting a ceramic core into a flexible mold of a core section and casting a ceramic shell in at least two sections into respective flexible molds of a first shell section and a second shell section. A ceramic casting vessel is subsequently formed by assembling the ceramic core within the ceramic shell sections. A metal substrate material is cast into the ceramic casting vessel. Removal of the ceramic casting vessel reveals a substrate of the component having defined therein the interior passageway, the one or more cooling passages in fluidic communication with the interior passageway and one or more surface grooves in fluidic communication with the one or more cooling passages.

What is claimed is: 
     
         1 . A method of casting a component including one or more surface cooling channels, the method comprising:
 casting a ceramic core from a flexible mold of one or more core sections;   casting a ceramic shell in at least two sections into respective flexible molds of at least two shell sections;   forming a ceramic casting vessel by assembling the ceramic core within the ceramic shell sections;   casting a metal substrate material into the ceramic casting vessel; and   removing the ceramic casting vessel to reveal a substrate of the component having defined therein an interior passageway, one or more cooling passages in fluidic communication with the interior passageway and one or more surface grooves in fluidic communication with the one or more cooling passages.   
     
     
         2 . The method of  claim 1 , further comprising:
 providing a model of a desired ceramic casting vessel defining a geometry of the component and including the interior passageway, the one or more cooling passages in fluidic communication with the interior passageway and the one or more surface grooves in fluidic communication with the one or more cooling passages;   digitally dividing the model into a plurality of sections defining the core section, the first shell section and the second shell section;   translating each of the plurality of sections into a master tool wherein the plurality of sections include a one or more precision metal inserts to define the geometry of the component including the interior passageway, the one or more cooling passages and the one or more surface grooves; and   casting the flexible molds from each master tool.   
     
     
         3 . The method of  claim 1 , further including disposing a coating over at least a portion of a surface of the substrate, wherein the one or more cooling passages, the one or more surface grooves and the coating define the one or more surface cooling channels for cooling the component. 
     
     
         4 . The method of  claim 1 , further including defining at least one coolant exit through the coating. 
     
     
         5 . The method of  claim 1 , wherein the one or more surface grooves are re-entrant shaped grooves. 
     
     
         6 . A method of casting a component including one or more surface cooling channels, the method comprising:
 providing a model of a desired ceramic casting vessel defining a geometry of the component and including an interior passageway, one or more cooling passages in fluidic communication with the interior passageway and one or more surface grooves in fluidic communication with the one or more cooling passages;   digitally dividing the model into a plurality of sections;   translating each of the plurality of sections into a master tool wherein the plurality of sections include a one or more precision metal inserts to define the geometry of the component including the interior passageway, the one or more cooling passages, the one or more surface grooves and one or more alignment features;   casting a flexible mold from each master tool;   casting a ceramic core from a respective flexible mold;   casting a ceramic shell in at least two sections from a respective flexible mold;   forming the ceramic casting vessel by assembling the ceramic core within the ceramic shell sections;   casting a metal into the ceramic casting vessel; and   removing the ceramic casting vessel to reveal a substrate of the component having the interior passageway, the one or more cooling passages in fluidic communication with the interior passageway and one or more surface grooves in fluidic communication with the one or more cooling passages.   
     
     
         7 . The method of  claim 6 , further including disposing a coating over at least a portion of a surface of the substrate, wherein the one or more surface grooves and the coating define the one or more surface cooling channels for cooling the component. 
     
     
         8 . The method of  claim 7 , wherein the coating completely bridges the respective one or more surface grooves such that the coating seals the respective one or more surface cooling channels. 
     
     
         9 . The method of  claim 6 , wherein the one or more surface grooves are re-entrant shaped grooves. 
     
     
         10 . The method of  claim 6 , wherein each of the master tools is formed of a metal material. 
     
     
         11 . The method of  claim 10 , wherein the metal material is aluminum. 
     
     
         12 . The method of  claim 6 , wherein the plurality of sections define one or more core sections and at least two shell sections. 
     
     
         13 . The method of  claim 6 , wherein the precision inserts are formed of a metal material. 
     
     
         14 . The method of  claim 13 , wherein the metal material is etched copper. 
     
     
         15 . The method of  claim 6 , wherein the one or more precision metal inserts further define one or more alignment features and wherein forming the ceramic casting vessel by assembling the ceramic core within the ceramic shell sections further includes utilizing the one or more alignment features. 
     
     
         16 . A method of casting a component including one or more surface cooling channels, the method comprising:
 providing a model of a desired ceramic casting vessel defining a geometry of the component and including an interior passageway, one or more cooling passages in fluidic communication with the interior passageway and one or more surface grooves in fluidic communication with the one or more cooling passages;   digitally dividing the model into a plurality of sections, wherein the plurality of sections define one or more core sections and at least two shell sections;   translating each of the plurality of sections into a master tool and disposing one or more precision metal inserts into one or more of the plurality of sections to define the geometry of the component including the interior passageway, the one or more cooling passages, the one or more surface grooves and one or more alignment features;   casting a flexible mold from each master tool;   assembling the respective flexible molds to define a cavity therebetween;   casting a ceramic core from a respective flexible mold;   casting a ceramic shell in at least two sections from a respective flexible mold;   forming the ceramic casting vessel by assembling the ceramic core within the ceramic shell sections utilizing the one or more alignment features;   casting a metal into the ceramic casting vessel;   removing the ceramic casting vessel to reveal a substrate of the component having the interior passageway, the one or more cooling passages in fluidic communication with the interior passageway and one or more surface grooves in fluidic communication with the one or more cooling passages; and   disposing a coating over at least a portion of a surface of the substrate, wherein the one or more surface grooves and the coating define the one or more surface cooling channels for cooling the component.   
     
     
         17 . The method of  claim 16 , wherein the coating completely bridges the respective one or more surface grooves such that the coating seals the respective one or more surface cooling channels. 
     
     
         18 . The method of  claim 16 , wherein the one or more surface grooves are re-entrant shaped grooves. 
     
     
         19 . The method of  claim 16 , wherein each of the master tools is formed of aluminum. 
     
     
         20 . The method of  claim 16 , wherein the precision inserts are formed of an etched copper.