Composite, internal reinforced ceramic cores and related methods
First Claim
1. A method of improving structural stability of a ceramic core used in the casting of hollow components comprising the steps of:
- a) providing a die having a geometry which gives the ceramic core a shape corresponding to interior spaces in the component;
b) inserting elongated strengthening members into one or more interior areas of said die corresponding to said interior spaces, said strengthening members having a length substantially equal to a corresponding length of said interior passages and said strengthening members being made of a material selected from the group consisting of alumina, quartz, molybdenum, tungsten and tungsten carbide;
c) injecting a ceramic slurry into said die so as to completely enclose said strengthening members; and
d) firing the ceramic slurry to form a hardened ceramic core.
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Accused Products
Abstract
A method of improving structural stability of a ceramic core used in the casting of turbine components includes the steps of a) providing a die having a predetermined geometry which gives the ceramic core a shape corresponding to interior spaces in the turbine component; b) inserting elongated strengthening members into interior or more areas of the die corresponding to one or more of the interior spaces; c) injecting a ceramic slurry into the die so as to substantially enclose the strengthening members; and d) firing the ceramic slurry to form a hardened ceramic core. A ceramic core used in a high temperature gas turbine component casting process includes a ceramic body having a geometry corresponding to internal passages of a gas turbine component; and at least one elongated rod or tube incorporated in the ceramic body, the rod or tube comprised of a material which retains structural stability at temperatures in excess of about 2600° F. In a method of casting a gas turbine component having interior passages, and including inserting a ceramic core in a casting die wherein the ceramic core is shaped to correspond to the interior passages, pouring molten metal into the die, and solidifying the molten metal and extracting the ceramic core, an improvement is disclosed which includes incorporating at least one strengthening member in the ceramic core to improve structural stability of the core during pouring and solidifying the molten metal.
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Citations
19 Claims
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1. A method of improving structural stability of a ceramic core used in the casting of hollow components comprising the steps of:
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a) providing a die having a geometry which gives the ceramic core a shape corresponding to interior spaces in the component; b) inserting elongated strengthening members into one or more interior areas of said die corresponding to said interior spaces, said strengthening members having a length substantially equal to a corresponding length of said interior passages and said strengthening members being made of a material selected from the group consisting of alumina, quartz, molybdenum, tungsten and tungsten carbide; c) injecting a ceramic slurry into said die so as to completely enclose said strengthening members; and d) firing the ceramic slurry to form a hardened ceramic core. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A ceramic core used in a high temperature hollow component casting process, comprising:
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a ceramic body having a geometry corresponding to internal passages of a hollow component; and a strengthening member comprising at least one elongated rod or tube completely enclosed within said ceramic body, said rod or tube made of a material which retains structural stability at temperatures in excess of about 2600°
F. - View Dependent Claims (11, 12, 13, 14, 19)
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- 15. In a method of casting a gas turbine component having interior passages, and including inserting a ceramic core into a casting die wherein the ceramic core is shaped to correspond to said interior passages, pouring molten metal into said die, solidifying said molten metal and extracting said ceramic core, an improvement comprising incorporating at least one strengthening member in said ceramic core to improve structural stability of said core during pouring and solidifying said molten metal, said strengthening member consisting of a solid rod completely enclosed within said core and having a length substantially equal to a corresponding length of said interior passages, and wherein said strengthening member is made of a material selected from the group consisting of alumina, quartz, molybdenum, tungsten and tungsten carbide.
Specification