Soluble Casting Core For Metal Matrix Composite Components and Method of Producing Thereof

Abstract

A process for manufacturing a soluble casting core for use in casting complex shaped metal matrix composite components. The soluble casting core is generated by a sequence of steps which provide a molten slurry mixture composed of an alkali metal salt such as sodium carbonate and a plurality of ceramic particulates such as magnesium oxide dispersed therein. After heating and mixing the slurry mixture is solidified in a mold pattern to form a casting core configured to generate a complex shaped component during a casting process. The soluble casting core is used for casting molten metal alloys therein, without failure of the casting surfaces and forming of a complex shaped metal matrix composite component. The soluble casting core is readily dissolved and separated from the soluble casting core by immersing the core mold in heated water and/or exposing to steam, without damage to the metal matrix composite component.

1 - 16 . (canceled)  
   
   
       17 . A casting core composed of soluble material for use in casting a complex shaped metal component, comprising: 
 a solidified mold pattern composed of a water soluble metal salt having a plurality of ceramic particulates in a selected continuous size range dispersed throughout, said solidified mold pattern formed to include a designed core shape configured to substantially duplicate a complex shaped metal component;    whereby upon said solidified mold pattern being used to cast the complex shaped metal component, said solidified mold pattern is readily separated from the complex shaped metal component by dissolution in heated water.    
   
   
       18 . The casting core of  claim 17  wherein said water soluble metal salt includes a sodium carbonate compound composing between about 50% to about 97% by weight percentage of said solidified mold pattern.  
   
   
       19 . The casting core of  claim 18  wherein said plurality of ceramic particulates in said selected continuous size range includes a plurality of magnesium oxide particulates having a powder size selected from the range of between about 5 microns to less than 150 microns, said plurality of magnesium oxide particulates being evenly disposed throughout said solidified mold pattern.  
   
   
       20 . The casting core of  claim 19  wherein said plurality of magnesium oxide particulates composing between about 3% to about 50% by weight percentage of said solidified mold pattern.  
   
   
       21 . A solidified casting core for casting a complex shaped metal component, comprising: 
 water soluble metal salt composed of molten sodium carbonate in a weight percentage of about 50% to about 97%; and    ceramic particulates composed of magnesium oxide particulates in a weight percentage of about 3% to about 50%, said magnesium oxide particulates having a powder size selected in a selected continuous size range of between about 5 microns to about 140 microns.    
   
   
       22 . The solidified casting core of  claim 21 , wherein said water soluble metal salt includes a proportion of about 95 parts of molten sodium carbonate, and said ceramic particulates include a proportion of about 5 parts of magnesium oxide particulates having the powder size of between about 5 microns to about 140 microns.