System, method, and apparatus for leaching cast components

US8828214B2 · kind B2 · utility

Assignees

• Rolls-Royce Corporation · US
• Rolls-Royce North American Technologies Inc. · US

Inventors

• Michel S. Smallwood · Greenwood, US
• Tab M. Heffernan · Indianapolis, US
• Mark McCormick · Windom, US
• Randolph C. Helmink · Indianapolis, US
• Matthew T. Kush · Greenwood, US

Key dates

• Filing date: Dec 28, 2011
• Grant date: Sep 9, 2014
• Expiry date: Mar 22, 2032

Classification

• Technology area (CPC C): Chemistry; Metallurgy
• CPC primary: C23G1/00
• WIPO field: Materials, metallurgy
• WIPO sector: Chemistry

Abstract

A method includes removing a casting shell and core from a cast component, which may be a gas turbine blade. The method further includes utilizing a focused removal technique, such as a water jet or laser drill, to remove a portion of a virtual pattern cast (VPC) shell from the cast component. The cast component is then exposed to a leaching solution and high pressure water wash to remove an internal core material and a portion of the VPC shell remainder from the cast component. The method further includes exposing the cast component to a high agitation leaching solution and to the high pressure water wash for a minimal time. An electroless nickel-boron coating is then applied to the cast component, and an electrolytic palladium coating is further applied to the cast component. The cast component is further exposed to a high agitation leaching solution for an extended period.