Ceramic core with composite insert for casting airfoils

摘要

A multi-wall ceramic core for casting an airfoil with one or more internal cooling passages is made by preforming at least one fugitive core insert to have a joint-forming surface with a male and/or female joint feature and then forming at least one fugitive core insert in-situ adjacent and integrally connected and fused to the at least one preformed core insert at the joint-forming surface to form an interlocked, fused joint to form a composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. Another aspect involves preforming first and second fugitive core inserts to have respective joint-forming surfaces with respective snap-fittable joint features and assembling the first and second fugitive core inserts to form a composite core insert by snap fitting the snap-fittable joint features together to form an interlocked joint. The composite core insert is placed in a core molding die cavity, and a fluid ceramic material is introduced into the die cavity to form the ceramic core body incorporating the fugitive composite core insert therein.

主权项

1. Combination of a multi-wall ceramic core for casting a hollow airfoil and a fugitive composite core insert that comprises at least one preformed fugitive core insert having joint-forming surface with a male and/or female joint feature and at least one fugitive core insert formed in-situ adjacent and integrally fused thereto at said joint-forming surface to provide an interlocked, fused joint having an interlocked male joint feature and female joint feature and having surfaces for forming passage surfaces in the core when the composite core insert is removed, wherein some of said surfaces reside in different planes.