Abstract: Apparatus and method for use in firing a ceramic casting core includes a saggar and a core setter insert disposed in the saggar. The core setter insert can be disposed on a refractory particulate grog bed and/or refractory supports inside the saggar on a bottom wall of the saggar. The core setter insert has a core-receiving surface, which can have an airfoil shape to receive an airfoil-shaped ceramic casting core used in casting hollow airfoil castings.

Abstract: A method of making a ceramic setter comprises forming a mixture of ceramic particulates and a binder to a shape of a green ceramic setter. The green ceramic setter then is placed on a metallic support member such that air ingress is provided therebetween for allowing access of air to the surface of the setter adjacent the support member. The green setter on the support member is placed in a burn-out hood. A volatile constituent of the biinder is ignited to burn off excess volatile constituent. The air ingress allows ambient air to reach the bottom surface of the green setter adjacent to the support member as well as the top surface of the green setter such that the volatile constituent of the binder is ignited and burned at both the top and bottom surfaces of the green setter. Use of the support member in this manner results in a significant reduction in green setter contour distortion during the burn-out operation.

Abstract: A method for firing a ceramic core includes placing the ceramic core on a setter, placing at least one flexible refractory bag containing refractory particulates on the core to apply a force on the core toward the setter during firing, and then heating the ceramic core on the setter to an elevated superambient firing temperature. Heating of the ceramic core with the flexible weight bag(s) thereon conforms the core to a surface of the setter to reduce distortion of the core and improve yields of cores within preselected dimensional tolerances.