Method for forming a directionally solidified replacement body for a component using additive manufacturing
A method of manufacturing a replacement body for a component is provided. The method includes the steps of: a) additively manufacturing a crucible for casting of the replacement body; b) solidifying a metal material within the crucible to form a directionally solidified microstructure within the replacement body; and c) removing the crucible to reveal the directionally solidified replacement body.
1. A method of manufacturing a replacement body for a component, comprising:
additively manufacturing the replacement body with a metal material;
forming a core at least partially within the replacement body;
at least partially encasing the replacement body and the core within a shell;
melting the additively manufactured replacement body;
solidifying the metal material of the additively manufactured replacement body to form a directionally solidified microstructure within the component; and
removing the shell and the core to reveal the directionally solidified microstructure replacement body.
2. The method of claim 1 , wherein the step of forming the core includes additively manufacturing the core.
3. The method of claim 1 , wherein the step of solidifying the metal material includes directionally solidifying the material to have a single crystal microstructure.
4. The method of claim 1 , wherein the step of solidifying the metal material includes directionally solidifying the material to have a columnar grain microstructure.
5. The method of claim 1 , wherein the core at least partially defines at least one internal passageway within the replacement body.
6. The method of claim 5 , further comprising the step of concurrently additively manufacturing the replacement body and the core within the replacement body.
7. The method of claim 5 , wherein the core at least partially defines at least one microchannel within the replacement body.
8. The method of claim 7 , wherein the microchannel is additively manufactured of a refractory material and the internal passageway is additively manufactured of a ceramic material.
9. The method of claim 8 , wherein the additive manufacturing is performed by a multi-powder bed system.
10. The method of claim 1 , further comprising the step of applying a wax material at least partially onto the replacement body.
11. A method of manufacturing a replacement body for a component, comprising:
additively manufacturing a replacement body from a metal material;
forming a crucible around the replacement body;
melting and solidifying the replacement body within the crucible to form a directionally solidified microstructure within the replacement body; and
removing the crucible from the directionally solidified replacement body.
12. The method of claim 11 , wherein the step of solidifying the replacement body includes directionally solidifying the metal material of the replacement body to have a single crystal microstructure.
13. The method of claim 11 , wherein the step of solidifying the replacement body includes directionally solidifying the metal material of the replacement body to have a columnar grain microstructure.
14. The method of claim 11 , wherein the metal material is selected from the group consisting of a nickel based superalloy, cobalt based superalloy, iron based superalloy, and mixtures thereof.
15. The method of claim 11 , wherein the crucible is formed from a ceramic material slurry.