Method of making an aerofoil member for a gas turbine engine

Claim 1

A method of making a blade or vane structure for a gas turbine engine, the blade or vane structure including a hollow aerofoil member having an inner end and an outer end and a cooling air entry tube positioned therein, the cooling air entry tube having an inner end and an outer end and extending integrally from the inner end of the hollow aerofoil member toward the outer end of the hollow aerofoil member in a cantilevered relationship and spaced entirely from an interior surface of the hollow aerofoil member, said method comprising the steps of: injection molding a disposable tube piece; mounting said disposable tube piece in a die; injection molding ceramic in a fluid state into said die to fill the interior of said disposable tube piece; causing said ceramic to harden; removing said ceramic with the disposable tube piece embedded therein from said die; mounting said ceramic with said disposable tube piece embedded therein in a further die having a desired shape of a ceramic core; injecting more of said ceramic in a fluid state to fill the space between the outside of said disposable tube piece and said die; causing said more of said ceramic to harden; removing said ceramic core with the disposable piece embedded therein from said die; removing said disposable piece from said ceramic core; placing said ceramic core in a further die and injecting wax into all voids in the ceramic core and around the ceramic core to make a wax preform; forming a shell mold about the wax preform; removing the wax preform from the shell mold by melting; and then casting metal into said shell mold to make the aerofoil member and the cooling air entry tube.

Claim 2

A method of making a blade or vane structure for a gas turbine engine, the blade or vane structure including a hollow aerofoil member having an inner end and an outer end and a cooling air entry tube positioned therein, the cooling air entry tube having an inner end and an outer end and extending integrally from the inner end of the hollow aerofoil member toward the outer end of the hollow aerofoil member in a cantilevered relationship and spaced entirely from an interior surface of the hollow aerofoil member, said method comprising the steps of: injection molding a disposable tube piece; mounting said disposable tube piece in a die; injection molding ceramic in a fluid state into said die to fill the interior of said disposable tube piece; causing said ceramic to harden; removing said ceramic with the disposable tube piece embedded therein from said die; mounting said ceramic with said disposable tube piece embedded therein in a further die having a desired shape of a ceramic core; injecting more of said ceramic in a fluid state to fill the space between the outside of said disposable tube piece and said die; causing said more of said ceramic to harden; removing said ceramic core with the disposable piece embedded therein from said die; removing said disposable piece from said ceramic core; placing said ceramic core in a further die and injecting wax into all voids in the ceramic core and around the ceramic core to make a wax preform; forming a shell mold about the wax preform; removing the wax preform from the shell mold by melting; and then casting metal into said shell mold to make the aerofoil member and the cooling air entry tube.

Claim 3

A method of making a blade or vane structure for a gas turbine engine, the blade or vane structure including a hollow aerofoil member having an inner end and an outer end and a cooling air entry tube positioned therein, the cooling air entry tube having an inner end and an outer end and extending integrally from the inner end of the hollow aerofoil member toward the outer end of the hollow aerofoil member in a cantilevered relationship and spaced entirely from an interior surface of the hollow aerofoil member comprising the steps of: injection moulding a first part of a disposable tube piece, injection moulding a second part of a disposable tube piece, assembling said first and second parts together to form a disposable tube piece, mounting said disposable tube piece in a die, injection moulding ceramic in a fluid state into said die to fill the interior of said disposable tube piece, causing said ceramic to harden, removing said ceramic with said disposable tube piece embedded therein from said die, mounting said ceramic with said disposable tube piece embedded therein in a further die having the desired shape of a ceramic core, injecting more of said ceramic in a fluid state to fill the space between the outside of said disposable tube piece and said die, causing said more of said ceramic to harden, removing said disposable piece from said ceramic core, placing said ceramic core in a further die and injecting wax into all voids in the ceramic core and around the ceramic core to make a wax preform; forming a shell mold about the wax preform; removing the wax preform from the shell mold by melting; and then casting metal into said shell mold to make the aerofoil member and the cooling air entry tube.

Claim 4

A method of making a blade or vane structure for a gas turbine engine, the blade or vane structure including a hollow aerofoil member having an inner end and an outer end and a cooling air entry tube positioned therein, the cooling air entry tube having an inner end and an outer end and extending integrally from the inner end of the hollow aerofoil member toward the outer end of the hollow aerofoil member in a cantilevered relationship and spaced entirely from an interior surface of the hollow aerofoil member comprising the steps of: injection moulding a first part of a disposable tube piece, injection moulding a second part of a disposable tube piece, assembling said first and second parts together to form a disposable tube piece, mounting said disposable tube piece in a die, injection moulding ceramic in a fluid state into said die to fill the interior of said disposable tube piece, causing said ceramic to harden, removing said ceramic with said disposable tube piece embedded therein from said die, mounting said ceramic with said disposable tube piece embedded therein in a further die having the desired shape of a ceramic core, injecting more of said ceramic in a fluid state to fill the space between the outside of said disposable tube piece and said die, causing said more of said ceramic to harden, removing said disposable piece from said ceramic core, placing said ceramic core in a further die and injecting wax into all voids in the ceramic core and around the ceramic core to make a wax preform; forming a shell mold about the wax preform; removing the wax preform from the shell mold by melting; and then casting metal into said shell mold to make the aerofoil member and the cooling air entry tube.