Method including fiber reinforced casting article

Abstract

A method of forming an engine component according to an exemplary aspect of the present disclosure includes, among other things, introducing molten metal into a cavity between a shell and a casting article in the shell. The casting article includes a ceramic portion and a plurality of fibers. The method further includes separately removing the ceramic portion and the fibers from an interior of the component.

What is claimed is: 
     
         1 . A method of forming an engine component, comprising:
 introducing molten metal into a cavity between a shell and a casting article in the shell, the casting article including a ceramic portion and a plurality of fibers; and   separately removing the ceramic portion and the fibers from an interior of the component.   
     
     
         2 . The method as recited in  claim 1 , further comprising:
 cooling the molten metal, wherein the plurality of fibers and the ceramic portion are removed after the molten metal cools.   
     
     
         3 . The method as recited in  claim 2 , wherein the ceramic portion is removed from the component using a leaching fluid, and the fibers are mechanically removed from the component. 
     
     
         4 . The method as recited in  claim 3 , wherein the fibers are blown out of the component using a pressurized fluid. 
     
     
         5 . The method as recited in  claim 4 , wherein the pressurized fluid is pressurized air. 
     
     
         6 . The method as recited in  claim 4 , wherein a maximum length of the fibers is less than a smallest orifice formed in the engine component. 
     
     
         7 . The method as recited in  claim 1 , wherein the fibers dissolve during the introducing step. 
     
     
         8 . The method as recited in  claim 7 , wherein the fibers fully dissolve during the introducing step. 
     
     
         9 . The method as recited in  claim 7 , wherein, after the molten metal cools, the remainder of the casting article is removed from the component using a leaching fluid. 
     
     
         10 . The method as recited in  claim 7 , wherein the size and chemical composition of the fibers is selected such that the fibers will intentionally dissolve during the introducing step. 
     
     
         11 . The method as recited in  claim 1 , wherein the fibers are randomly oriented within the ceramic portion. 
     
     
         12 . The method as recited in  claim 11 , wherein the ceramic portion includes alumina (Al 2 O 3 ). 
     
     
         13 . The method as recited in  claim 1 , wherein the fibers are provided by one of (1) silicon (Si) fibers, (2) carbon (C) fibers, and (3) metal fibers. 
     
     
         14 . A method of forming an engine component, comprising:
 introducing molten metal into a cavity between a shell and a casting article, the casting article including a ceramic portion and a plurality of fibers;   dissolving the fibers during the introducing step; and   removing the remainder of the casting article from the interior of the component using a leaching fluid.   
     
     
         15 . The method as recited in  claim 14 , wherein the size and material of the fibers is selected such that the fibers will intentionally dissolve during the introducing step. 
     
     
         16 . The method as recited in  claim 14 , wherein the fibers completely dissolve during the introducing step. 
     
     
         17 . The method as recited in  claim 14 , wherein the ceramic portion includes alumina (Al 2 O 3 ). 
     
     
         18 . The method as recited in  claim 14 , wherein the fibers are provided by one of (1) silicon (Si) fibers, (2) carbon (C) fibers, and (3) metal fibers. 
     
     
         19 . A method of forming an engine component, comprising:
 providing a ceramic shell and a casting article, the casting article including a ceramic portion and a plurality of fibers;   sintering the ceramic shell and the casting article, wherein the plurality of fibers are dissolved by the sintering step;   introducing a molten metal between the shell and the casting article; and   removing the remainder of the casting article from the interior of the component.