Turbine component casting core with high resolution region

摘要

A hollow turbine engine component with complex internal features can include a first region and a second, high resolution region. The first region can be defined by a first ceramic core piece formed by any conventional process, such as by injection molding or transfer molding. The second region can be defined by a second ceramic core piece formed separately by a method effective to produce high resolution features, such as tomo lithographic molding. The first core piece and the second core piece can be joined by interlocking engagement that once subjected to an intermediate thermal heat treatment process thermally deform to form a three dimensional interlocking joint between the first and second core pieces by allowing thermal creep to irreversibly interlock the first and second core pieces together such that the joint becomes physically locked together providing joint stability through thermal processing.

主权项

1. A method of forming a core for use in casting a turbine engine component comprising:
forming a normal resolution region of the core using a first process of molding; and forming a high resolution region of the core using lithographic molding, which is a method of molding different than the first process and effective to produce high resolution features; wherein the high resolution region has one or more high resolution features selected from the group consisting of a recess, cavity, opening, protrusion, channel, groove, slot, and depression; wherein the normal resolution region is defined by a first core piece and the high resolution region is defined by a second core piece; wherein the first core piece includes a cavity therein; wherein the second core piece includes a protrusion, joining the first and second core pieces such that a first portion of the protrusion is received in at least a portion of the cavity; heating the protrusion via an intermediate thermal heat treatment process causing the protrusion to thermally deform to create a three dimensional interlocking joint between the first and second core pieces by allowing thermal creep to irreversibly interlock the first and second core pieces together such that the joint becomes physically locked together providing joint stability through thermal processing; wherein the cavity is offset from a lateral contact surface such that the cavity is exposed through the first core piece via a neck having a cross-sectional area that is less than the cavity; and inserting a locking member into the cavity housing the protrusion and into at least a portion of space in the cavity which was vacated by the protrusion once the protrusion was thermally deformed during the intermediate thermal heat treatment process.