Method and apparatus for improving core manufacturing for gas turbine components

A method of producing a core for a gas turbine component casting comprising:

• forming a sacrificial core die insert from water-soluble material;
• providing an adapter insert, the adapter insert having a first portion and a second portion, the first portion and the second portion being selectively separable;
• providing a core injection tool including a cavity block having a recessed cavity, the cavity block having an upper portion, a lower portion, a feed plate, and a channel in communication with the feed plate;
• positioning the adapter insert and the core die insert within the cavity block such that the adapter insert is situated within the recessed cavity and the core die insert is situated within the adapter insert;
• directing a ceramic-based core material into the core die insert via the feed plate and through the channel;
• applying pressure to the core die insert through the cavity block and the adapter insert;
• and
• permitting solidification of the ceramic-based core material within the core die insert;
• wherein, an internal profile of the core die insert corresponds to an external profile of the core for a gas turbine component casting.

A method of producing a core for a gas turbine component casting comprising:

• using a core injection tooling including a cavity block having an upper portion, a lower portion, a locking mechanism configured to secure the upper portion and the lower portion together, and a recessed cavity in each of the upper portion and the lower portion;
• using an adapter insert sized to fit within the recessed cavities, the adapter insert having a first portion and a second portion, the first portion and the second portion being selectively separable;
• using an additive manufacturing process to fabricate a core die insert comprising sacrificial material;
• situating the adapter insert within the recessed cavities and the core die insert within the adapter insert;
• directing a ceramic-based core material into the core die insert;
• applying pressure to the core die insert through the adapter insert and the cavity block;
• permitting solidification of the ceramic-based core material within the core die insert;
• and
• removing the core from the core die insert.