Metallic Coated Cores to Facilitate Thin Wall Casting

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.

1 . A core for investment casting processes, comprising:
 one or more ceramic materials; and   a layer of metal atop the one or more ceramic materials.   
     
     
         2 . The core of  claim 1 , wherein said one or more ceramic materials are selected from the group consisting of silica based ceramic materials, alumina based ceramic materials and combinations thereof. 
     
     
         3 . The core of  claim 1 , wherein the one or more ceramic materials form a ceramic coating atop one or more refractory metal cores. 
     
     
         4 . The core of  claim 3 , wherein said one or more refractory metal cores are selected from the group consisting of molybdenum, niobium, tantalum and tungsten. 
     
     
         5 . The core of  claim 1 , wherein said ceramic material comprises a material selected from the group consisting of silica, alumina, zirconia, chromia, mullite and hafnia. 
     
     
         6 . The core of  claim 1 , wherein said metal comprises a noble metal. 
     
     
         7 . The core of  claim 1 , wherein said metal comprises a metal selected from the group consisting of Group VIII, Group VIIIA and Group IB. 
     
     
         8 . The core of  claim 1 , wherein said exterior layer of said metal is a layer of sputtered metal material. 
     
     
         9 . The core of  claim 1 , wherein said layer of said metal is a layer of plated metal material. 
     
     
         10 . A method for casting a turbine engine component having an internal passageway, comprising:
 forming one or more mold sections each having internal surfaces and at least one core comprising a layer of metal compatible with a casting material for forming one or more turbine engine components having at least one internal passageway, said layer of metal atop one or more ceramic materials;   introducing a molten alloy into the one or more assembled mold sections; and   consuming said layer of said metal of said at least one core.