Manufacturing method and tooling for ceramic cores

Abstract

A method of manufacturing a tooling assembly and the tooling assembly (10) for ceramic cores. The tooling assembly includes a backing plate (12) comprising a top surface (20), side surfaces (18), and a bottom surface (16) and a plurality of lithographically derived inserts (14) each comprising a bottom surface (24), side surfaces (26), and a positive top surface (28) and pieced together on the top surface (20) of the backing plate (12). The method includes providing the backing plate (12) and plurality of lithographically derived inserts (14). A non-conformal positive surface is generated from the plurality of lithographically derived inserts (14). A negative flexible mold is created from the non-conformal positive surface. The negative flexible mold is then prepared for casting for an advanced ceramic core.

What is claimed is: 
     
         1 . A master tooling assembly for ceramic cores, comprising:
 a backing plate comprising a top surface, side surfaces, and a bottom surface;   a plurality of lithographically derived inserts each comprising a bottom surface, side surfaces, and a positive top surface, wherein the plurality of lithographically derived inserts are pieced together on the top surface of the backing plate;   a second backing plate comprising a top surface, side surfaces, and a bottom surface; and   a second plurality of lithographically derived inserts each comprising a bottom surface, side surfaces, and a positive top surface, wherein the plurality of lithographically derived inserts are pieced together on the top surface of the second backing plate.   
     
     
         2 . The master tooling assembly of  claim 1 , wherein the backing plate and second backing plate are each a single step machined surface. 
     
     
         3 . The master tooling assembly of  claim 1 , wherein the plurality of lithographically derived inserts comprises one hundred percent surface coverage over the backing plate. 
     
     
         4 . The master tooling assembly of  claim 1 , wherein the plurality of lithographically derived inserts are pieced together by location features in the master tool surface. 
     
     
         5 . The master tooling assembly of  claim 1 , wherein the plurality of lithographically derived inserts are pieced together by contour location and interlocking edge features of the lithographically derived inserts. 
     
     
         6 . The master tooling assembly of  claim 1 , wherein the plurality of lithographically derived inserts are pieced together by suction ports located in the master tool. 
     
     
         7 . The master tooling assembly of  claim 1 , wherein the plurality of lithographically derived inserts are pieced together by reversible thin layer bonding media. 
     
     
         8 . A method of manufacturing of a tooling assembly for ceramic cores, comprising:
 providing a plurality of lithographically derived inserts and a second plurality of lithographically derived inserts each comprising a bottom surface, side surfaces, and a positive top surface;   providing a backing plate and a second backing plate each comprising a top surface, side surfaces and a bottom surface, the backing plate and the second backing plate provided as a locator surface;   generating a non-conformal positive surface from the plurality of lithographically derived inserts pieced together and placed on the backing plate;   generating a non-conformal positive surface from the second plurality of lithographically derived inserts pieced together and placed on the second backing plate;   creating a first negative flexible transfer mold from the non-conformal positive surface of the plurality of lithographically derived inserts;   creating a second negative flexible transfer mold from the non-conformal positive surface of the second plurality of lithographically derived inserts; and   preparing the negative flexible molds for casting an advanced ceramic core.   
     
     
         9 . The method of tooling of  claim 8 , wherein the backing plate and the second backing plate are each a single step machined surface. 
     
     
         10 . The method of  claim 8 , wherein the advanced ceramic core is for a component within the power industry. 
     
     
         11 . The method of  claim 8 , wherein the advanced ceramic core is for a turbine blade.