Composite, internal reinforced ceramic cores and related methods

Abstract

A method of improving structural stability of a ceramic core used in the casting of turbine components includes the steps of a) providing a die having a predetermined geometry which gives the ceramic core a shape corresponding to interior spaces in the turbine component; b) inserting elongated strengthening members into interior or more areas of the die corresponding to one or more of the interior spaces; c) injecting a ceramic slurry into the die so as to substantially enclose the strengthening members; and d) firing the ceramic slurry to form a hardened ceramic core. A ceramic core used in a high temperature gas turbine component casting process includes a ceramic body having a geometry corresponding to internal passages of a gas turbine component; and at least one elongated rod or tube incorporated in the ceramic body, the rod or tube comprised of a material which retains structural stability at temperatures in excess of about 2600.degree. F. In a method of casting a gas turbine component having interior passages, and including inserting a ceramic core in a casting die wherein the ceramic core is shaped to correspond to the interior passages, pouring molten metal into the die, and solidifying the molten metal and extracting the ceramic core, an improvement is disclosed which includes incorporating at least one strengthening member in the ceramic core to improve structural stability of the core during pouring and solidifying the molten metal.

Dependencies are inferred from the claim text.