Abstract: A core forming method is provided for forming a core. The core forming method includes forming one or more mold parts of water-soluble polymer (WSP), each mold part including a bond area and a part forming area, moistening the bond areas, bonding the mold parts together with the bond areas moistened and the part forming areas aligned to form a cavity shaped as a negative of the core, injecting a slurry, which is non-reactive with the WSP, into the cavity and removing the WSP with water once the slurry is cured.

Abstract: A method for producing a flexible mold for casting a ceramic core, the ceramic core used for an investment casting, is presented. The method includes forming a consumable master tool by 3D-printing, producing the flexible mold from the master tool, allowing the flexible mold to cure, and removing the consumable master tool. The master tool includes a negative surface geometry representative of the flexible mold to be produced.

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 having 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.

Abstract: A core forming method is provided for forming a core. The core forming method includes forming one or more mold parts of water-soluble polymer (WSP), each mold part including a bond area and a part forming area, moistening the bond areas, bonding the mold parts together with the bond areas moistened and the part forming areas aligned to form a cavity shaped as a negative of the core, injecting a slurry, which is non-reactive with the WSP, into the cavity and removing the WSP with water once the slurry is cured.

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.

Abstract: A method of manufacturing protruding cast in features (10). At least one core insert (12) is manufactured using small particle sizes. A bulk core body is manufactured using large particle sizes. The at least one core insert (12) and bulk core body are fully fired separately. The at least one core insert (12) is bonded with the bulk core body.

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.

Abstract: A method of manufacturing protruding cast in features (10). At least one core insert (12) is manufactured using small particle sizes. A bulk core body is manufactured using large particle sizes. The at least one core insert (12) and bulk core body are fully fired separately. The at least one core insert (12) is bonded with the bulk core body.

Abstract: A hard tool configuration and method of manufacturing advanced detailed trailing edge features in a core for casting. The hard tool configuration includes at least a first platform and a second platform. The hard tool configuration also includes a first end of a plurality of removable rake elements removably attached to at least one of the first platform and the second platform. The hard tool configuration also includes an internal mold geometry in a spacing in between the center facing side of the first platform and the center facing side of the second platform.

Abstract: A hard tool configuration (28) and method of manufacturing advanced detailed trailing edge features in a core for casting. The hard tool configuration (28) includes at least a first platform (10) and a second platform (12). The hard tool configuration (28) also includes a first end (22) of a plurality of removable rake elements (14) removably attached to at least one of the first platform (10) and the second platform (12). The hard tool configuration (28) also includes an internal mold geometry (18) in a spacing in between the center facing side (16) of the first platform (10) and the center facing side (16) of the second platform (12).