US2016319677A1PendingUtilityA1

Single crystal parts using additive manufacturing and remelt

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Assignee: UNITED TECHNOLOGIES CORPPriority: Apr 19, 2013Filed: Jul 15, 2016Published: Nov 3, 2016
Est. expiryApr 19, 2033(~6.7 yrs left)· nominal 20-yr term from priority
Inventors:John McbrienLea Kennard CastleBrandon W. Spangler
B22F 10/25F01D 5/28B22F 10/28B22C 7/02B22C 9/043B22C 9/061B22F 3/11B33Y 80/00F01D 9/02B22D 27/045C30B 11/00B22D 23/06B23P 6/00B32B 3/08B22F 5/04B23K 15/0006F01D 5/187B22C 9/108B22F 2998/10B32B 5/16B32B 9/005B22D 27/04B22C 9/22C30B 29/52B22C 9/101B22F 3/24B22D 25/02F01D 9/065F05D 2300/175B32B 2264/105F01D 25/12B22C 9/10B32B 2603/00B22F 2998/00F01D 5/18B32B 2250/03F01D 5/147F01D 5/282B32B 3/26B22C 9/24B33Y 10/00F23R 3/28B22C 9/02F05D 2230/31B22F 2003/248F05D 2300/211F01D 9/041F05D 2220/32B23K 26/342B23K 15/0086B32B 1/08F05D 2300/607B22F 3/1055Y02P10/25
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Claims

Abstract

A metal single crystal turbine component with internal passageways includes a polycrystalline turbine blade formed by additive manufacturing. The turbine component is remelted and directionally solidified to form the single crystal turbine component with internal passageways.

Claims

exact text as granted — not AI-modified
1 . A metal single crystal turbine component with internal passageways formed without the use of a wax pattern comprising:
 a metal turbine component with internal passageways formed by an additive manufacturing process, that is remelted and directionally solidified to form a metal single crystal turbine component.   
     
     
         2 . The turbine component of  claim 1 , wherein the internal passageways are filled with core ceramic before remelting. 
     
     
         3 . The turbine component of  claim 1 , wherein the turbine component and ceramic core are encased in a shell mold before remelting. 
     
     
         4 . The turbine component of  claim 3 , wherein the core ceramic material is selected from the group consisting of silica, alumina, zircon, cobalt, mullite, and kaolin, and mixtures thereof. 
     
     
         5 . The turbine component of  claim 3 , wherein the shell mold ceramic material is selected from the group consisting of silica, alumina, zircon, cobalt, mullite, and kaolin. 
     
     
         6 . The turbine component of  claim 1 , wherein the additive manufacturing process comprises at least one of selective laser sintering, selective laser melting, direct metal deposition, direct metal laser melting, and electron beam melting. 
     
     
         7 . The turbine component of  claim 1 , wherein the metal is selected from the group consisting of a nickel based superalloy, a cobalt based superalloy, an iron based superalloy, and mixtures thereof. 
     
     
         8 . The turbine component of  claim 1 , wherein the metal turbine component is attached to a starter seed or grain selector before remelting. 
     
     
         9 . The turbine component of  claim 3 , wherein the shell mold is fired between temperatures of about 1200° F. (649° C.) and about 1800° F. (982° C.) for times between about 10 and about 120 minutes.

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