Casting Cores and Manufacture Methods

Abstract

A casting core assembly includes a metallic core and a ceramic core. A protuberant portion of a metallic core is received in a compartment of the ceramic core.

1 . A casting core assembly comprising:
 a metallic core comprising:
 a metallic thickened portion forming a protuberance having a width at least twice its peak thickness; and 
 a metallic thin portion extending from the thickened portion; and 
   a ceramic core having a compartment in which the thickened portion is received.   
     
     
         2 . The assembly of  claim 1  further comprising:
 a ceramic adhesive joint between the thickened portion and the ceramic core. 
 
     
     
         3 . The assembly of  claim 1  wherein:
 the ceramic core is an airfoil feedcore; and 
 the metallic core is an outlet core. 
 
     
     
         4 . The assembly of  claim 1  wherein:
 the thickened portion is of increasing thickness from a proximal end toward a distal end. 
 
     
     
         5 . The assembly of  claim 1  wherein:
 the thickened portion has flat first and second faces at an angle of 1-15° relative to each other. 
 
     
     
         6 . The assembly of  claim 1  wherein:
 the thickened portion comprises consolidated metallic powder. 
 
     
     
         7 . The assembly of  claim 1  wherein:
 the thickened portion comprises a metallic laminate. 
 
     
     
         8 . A pattern comprising:
 the assembly of  claim 1 ;   a wax material in which the assembly is partially embedded.   
     
     
         9 . A mold comprising:
 the assembly of  claim 1 ; and   a shell, the metallic core having a distal portion embedded in the shell and the metallic core spanning a gap between the ceramic core and the shell.   
     
     
         10 . A process for forming the assembly of  claim 1 , the process comprising:
 inserting the thickened portion of the metallic core into the compartment in the ceramic core.   
     
     
         11 . The process of  claim 10  further comprising:
 securing the thickened portion to the ceramic core 
 
     
     
         12 . The process of  claim 11  wherein:
 the securing comprises introducing a ceramic adhesive between the thickened portion and the compartment. 
 
     
     
         13 . The process of  claim 10  wherein:
 the securing comprises introducing a non-ceramic adhesive between the thickened portion and the compartment. 
 
     
     
         14 . The process of  claim 10  further comprising:
 applying a coating to the metallic core. 
 
     
     
         15 . The process of  claim 10  further comprising:
 forming the thickened portion by laminating a plurality of additional sheets to a main sheet. 
 
     
     
         16 . The process of  claim 15  wherein:
 the laminating comprises welding. 
 
     
     
         17 . The process of  claim 15  wherein:
 the plurality of additional sheets are asymmetrically applied to the main sheet. 
 
     
     
         18 . The process of  claim 15  wherein:
 the plurality of additional sheets are symmetrically applied to the main sheet. 
 
     
     
         19 . The process of  claim 15  further comprising:
 machining the laminated sheets. 
 
     
     
         20 . The process of  claim 10  further comprising:
 forming the thickened portion by a powder process. 
 
     
     
         21 . The process of  claim 20  wherein:
 the powder process comprises a laser or electron beam melting or sintering. 
 
     
     
         22 . The process of  claim 10  further wherein:
 the metallic core comprises a by-weight majority of one or more refractory metals. 
 
     
     
         23 . The process of  claim 10  being a portion of a pattern-forming process and further comprising:
 overmolding a main pattern-forming material to the core assembly in a pattern-forming die. 
 
     
     
         24 . The process of  claim 23  being a portion of a shell-forming process, the shell-forming process further comprising:
 shelling the pattern; and 
 removing the further sacrificial material and main pattern-forming material and hardening the shell. 
 
     
     
         25 . The process of  claim 24  being a portion of a casting process, the casting process further comprising:
 introducing molten metal to the shell; 
 allowing the metal to solidify; and 
 destructively removing the shell and the core assembly. 
 
     
     
         26 . The process of  claim 25  wherein:
 the ceramic core forms a feed passageway in an airfoil; and 
 the metallic core forms an outlet passageway from the feed passageway to a pressure side or a suction side of the airfoil. 
 
     
     
         27 . The process of  claim 25  wherein:
 the securing comprises introducing a non-ceramic adhesive between the thickened portion and the compartment; and 
 the non-ceramic adhesive is vaporized or reacted off upon the introduction of the molten metal or before. 
 
     
     
         28 . The assembly of  claim 1  wherein:
 the peak thickness of the protuberance is at least four times a characteristic thickness of a main portion of the metallic core. 
 
     
     
         29 . The assembly of  claim 1  wherein:
 the protuberance forms a plug. 
 
     
     
         30 . The assembly of  claim 29  wherein:
 the plug has a shoulder surface merging with a face of a main portion of the metallic core along a tapering neck region.