Investment casting cores and methods

Abstract

A method involves forming a core assembly. The forming includes deforming a wire, the deforming including increasing a transverse linear dimension along at least one portion of the wire. The wire is assembled to a ceramic core

1 . A method comprising:
 forming a casting core assembly, the forming including:   deforming a wire, the deforming including increasing a transverse linear dimension along at least one portion of the wire; and   
     assembling the wire to a ceramic core. 
   
   
       2 . The method of  claim 1  wherein the increasing includes:
 increasing a transverse cross-sectional area along said portion.   
   
   
       3 . The method of  claim 1  wherein the increasing includes:
 decreasing a transverse cross-sectional area along said portion.   
   
   
       4 . The method of  claim 1  wherein the increasing includes:
 melting.   
   
   
       5 . The method of  claim 1  wherein the assembling comprises:
 inserting an end portion of the wire into a compartment of the ceramic core.   
   
   
       6 . The method of  claim 1  wherein the assembling comprises:
 inserting an intermediate portion of the wire into a compartment of the ceramic core.   
   
   
       7 . The method of  claim 6  wherein:
 the intermediate portion is a single intermediate portion and first and second ends of the wire are left out of the compartment.   
   
   
       8 . The method of  claim 1  wherein the forming further comprises:
 molding the ceramic core.   
   
   
       9 . The method of  claim 1  wherein the forming further comprises:
 machining the compartment into the ceramic core.   
   
   
       10 . The method of  claim 1  wherein the deforming includes:
 spiraling the wire.   
   
   
       11 . The method of  claim 1  further comprising:
 molding a pattern-forming material at least partially over the core assembly for forming a pattern;   shelling the pattern;   removing the pattern-forming material from the shelled pattern for forming a shell;   introducing molten alloy to the shell; and   removing the shell and core assembly.   
   
   
       12 . The method of  claim 11  used to form a gas turbine engine component. 
   
   
       13 . The method of  claim 11  used to form a gas turbine engine airfoil wherein the wire casts an outlet passageway. 
   
   
       14 . The method of  claim 13  wherein:
 the ceramic core casts a feed cavity; and   first and second portions of the wire cast respective first and second outlet passageways.   
   
   
       15 . An investment casting core combination comprising:
 a metallic wire casting core; and   a ceramic feedcore in which an intermediate portion of the metallic wire casting core is embedded.   
   
   
       16 . The investment casting core combination of  claim 15  further comprising:
 a plurality of additional metallic wire casting cores, each comprising:
 an intermediate portion in a compartment of the ceramic core; and 
 first and second end portions protruding from the compartment. 
   
   
   
       17 . An investment casting pattern comprising:
 the investment casting core combination of  claim 15 ; and   a wax material at least partially encapsulating the metallic wire casting core and the feedcore and having:
 an airfoil contour surface including:
 a leading edge portion; and 
 pressure and suction side portions extending from the leading edge portion, first and second end portions of the metallic wire casting core protruding from at least one of the pressure and suction side portions. 
 
   
   
   
       18 . An investment casting shell comprising:
 the investment casting core combination of  claim 15 ; and   a ceramic stucco at least partially encapsulating the metallic wire core and the feedcore; and   an airfoil contour interior surface including:
 a leading edge portion; and 
 pressure and suction side portions extending from the leading edge portion and formed by the ceramic stucco. 
   
   
   
       19 . A method comprising:
 forming a core assembly, the forming including:
 deforming a wire; and 
 assembling the wire to a ceramic core, including inserting an intermediate portion of the wire into a compartment of the ceramic core. 
   
   
   
       20 . The method of  claim 19  wherein the forming further comprises:
 molding the ceramic core.   
   
   
       21 . The method of  claim 19  wherein the forming further comprises:
 machining the compartment into the ceramic core.   
   
   
       22 . The method of  claim 19  wherein:
 the intermediate portion is a single intermediate portion and first and second ends of the wire are left out of the compartment.   
   
   
       23 . An investment casting core combination comprising:
 a metallic wire casting core having a portion of increased transverse dimension; and   a ceramic feedcore in which a portion of the metallic wire casting core is embedded.   
   
   
       24 . The investment casting core combination of  claim 23  wherein:
 said transverse dimension distally increases along at least a proximal region of the portion.