Casting cores and manufacture methods

Patent metadata

Field	Value
Publication number	US-9421606-B2
Application number	US-201314432790-A
Country	US
Kind code	B2
Filing date	Jul 24, 2013
Priority date	Oct 12, 2012
Publication date	Aug 23, 2016
Grant date	Aug 23, 2016

Abstract

A casting core assembly ( 140 ) includes a metallic core ( 144, 146, 148; 360; 380; 400 ) and a ceramic core ( 142 ). A protuberant portion ( 184 ) of a metallic core is received in compartment ( 186 ) of the ceramic core.

First claim

What is claimed is:

1. A casting core assembly comprising:
a metallic core comprising:
a thickened portion comprising a metallic laminate; and
a thin portion extending from the thickened portion;

a ceramic core having a compartment in which the thickened portion is received; and
an adhesive joint between the thickened portion and the ceramic core.

2. The assembly of claim 1 wherein:
the adhesive joint is 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.

6. The assembly of claim 1 wherein:
a main sheet of the metallic laminate extends along both the thickened portion and the thin portion; and
a plurality of additional sheets of the metallic laminate extend only along the thickened portion.

7. A pattern comprising:
the assembly of claim 1 ;
a wax material in which the assembly is partially embedded.

8. 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.

9. 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.

10. The process of claim 9 further comprising:
securing the thickened portion to the ceramic core.

11. The process of claim 10 wherein:
the securing comprises introducing a ceramic adhesive between the thickened portion and the compartment.

12. The process of claim 10 wherein:
the securing comprises introducing a non-ceramic adhesive between the thickened portion and the compartment.

13. The process of claim 9 further comprising:
applying a coating to the metallic core.

14. The process of claim 9 further comprising:
forming the thickened portion by laminating a plurality of additional sheets to a main sheet.

15. The process of claim 14 wherein:
the laminating comprises welding.

16. The process of claim 14 wherein:
the plurality of additional sheets are asymmetrically applied to the main sheet.

17. The process of claim 14 wherein:
the plurality of additional sheets are symmetrically applied to the main sheet.

18. The process of claim 14 further comprising:
machining the laminated sheets.

19. The process of claim 9 further wherein:
the metallic core comprises a by-weight majority of one or more refractory metals.

20. The process of claim 9 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.

21. A casting core assembly comprising:
a metallic core comprising:
a thickened portion comprising a metallic laminate and having flat first and second faces; and
a thin portion extending from the thickened portion, the first and second faces being not parallel and converging in a direction away from the direction in which the thin portion extends from the thickened portion; and

a ceramic core having a pre-formed compartment in which the thickened portion is received.

22. A casting core assembly comprising:
a metallic core comprising:
a thickened portion comprising a metallic laminate and having first and second faces; and
a thin portion extending from the thickened portion, the thin portion formed by a first sheet and the thickened portion comprising multiple stacked additional sheets on at least a first face of the first sheet;

a ceramic core having a pre-formed compartment in which the thickened portion is received and complementary in shape to the thickened portion; and
an adhesive joint between the thickened portion and the ceramic core.

23. The casting core assembly of claim 22 wherein:
a face of the thickened portion is formed by a second face of the first sheet.

Assignees

• United Technologies Corp

Inventors

• Propheter-Hinckley Tracy A
• Hansen Eric A

Classifications

• B22C9/04

  Use of lost patterns · CPC title

• B22C9/103 Primary

  Multipart cores · CPC title

• B22C9/108

  Installation of cores · CPC title

• B22C9/10

  Cores; Manufacture or installation of cores {(breaker cores B22C9/084)} · CPC title

• B22C7/02

  Lost patterns · CPC title