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, then forming at least one core insert in-situ adjacent and fused to the at least one preformed core insert by introducing fluid fugitive pattern material into a composite core insert mold whereby the fugitive core inserts are integrally connected as a single composite core insert that includes features to form internal passage surfaces in the core when the composite core insert is removed. 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.