Metallic coated cores to facilitate thin wall casting

• US 7,802,613 B2
• Filed: 01/30/2006
• Issued: 09/28/2010
• Est. Priority Date: 01/30/2006
• Status: Expired due to Fees

• Current Assignee: Raytheon Technologies Corporation d/b/a RTX
• Original Assignee: United Technologies Corporation (Raytheon Technologies Corporation d/b/a RTX)
• Inventors: Persky, Joshua E., Bullied, Steven J., Parkos, Joseph J. Jr.
• Primary Examiner(s): Kerns; Kevin P
• Application Number:
  US11/343,369
• Publication Number:
  US 20100219325A1
• Time in Patent Office: 1,702 Days
• Field of Search: 164/369, 164/361
• US Class Current: 164/369
• CPC Class Codes: B22C 3/00 Selection of compositions for coating the surfaces of moulds, cores, or patterns
• CPC Class Codes: B22C 9/04 Use of lost patterns
• CPC Class Codes: B22C 9/10 Cores; Manufacture or installation of cores breaker cores B22C9/084

Abstract

A core for investment casting processes includes a core having one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

Claims

1. A core for investment casting processes, comprising:

a core comprising a combination of one or more ceramic materials selected from the group consisting of silica based ceramic materials, alumina based ceramic materials and combinations thereof, and one or more refractory metal core materials selected from the group consisting of molybdenum, niobium, tantalum and tungsten; and

an exterior layer of a metal compatible with a casting material deposited upon an exterior surface of said core, said metal comprising a noble metal, wherein;

the exterior layer is on the one or more ceramic materials; and

said core includes a protective coating disposed between said exterior surface and said exterior layer, said protective coating is selected from the group consisting of silica, alumina, zirconia, chromia, mullite and hafnia.

2. The core of claim 1, wherein said metal comprises a metal selected from the group consisting of Group VIII, Group VIIIA and Group M.

3. The core of claim 1, wherein said exterior layer of said metal is a layer of sputtered metal material.

4. The core of claim 1, wherein said layer of said metal is a layer of plated metal material.