Refractory metal core finishing technique

1. A refractory metal core (RMC) finishing method, comprising:

performing a plurality of finishing operations on a plurality of RMC samples;

analyzing one or more properties of at least a portion of the plurality of RMC samples, wherein the one or more properties include at least break edge sharpness and surface finish;

based on the analyzing step, selecting a combination of finishing operations for generating an RMC [having desirable properties for manufacturing a part free from defects]; and

performing the combination of finishing operations to provide an RMC for manufacturing a part that is free from at least one of alloying, spallation and recrystallization.

2. The method as recited in claim 1 , wherein the part is a gas turbine engine casting.

3. The method as recited in claim 1 , wherein the plurality of finishing operations include a first harperizing process performed for a first amount of time and a second harperizing process performed for a second, different amount of time.

4. The method as recited in claim 3 , wherein the plurality of finishing operations include a robotic machining process.

5. The method as recited in claim 1 , wherein the plurality of finishing operations include at least two of harperizing, robotic machining, and etching.

6. The method as recited in claim 1 , the method comprising performing a plurality of validation operations on the plurality of RMC samples after the step of performing the plurality of finishing operations.

7. The method as recited in claim 6 , wherein the plurality of validation operations include at least one of a pull test, a furnace test and a casting process.

8. The method as recited in claim 1 , comprising the step of analyzing data concerning the RMC samples using a computer system.

9. A method, comprising:

performing a plurality of finishing operations on a plurality of refractory metal core (RMC) samples;

measuring break edge and surface finish properties associated with at least a portion of the plurality of RMC samples;

performing validation operations on the portion of the plurality of RMC samples;

based on the measuring step and the validation operations performed, selecting a combination of finishing operations for generating an RMC [having desirable properties for casting a part free from defects]; and

performing the combination of finishing operations to provide an RMC for manufacturing a part that is free from at least one of alloying, spallation and recrystallization.

10. The method as recited in claim 9 , wherein the step of performing the plurality of finishing operations includes:

performing a first finishing operation on a first portion of the plurality of RMC samples to round break edges; and

performing a second finishing operation on a second portion of the plurality of RMC samples to round break edges.

11. The method as recited in claim 10 , comprising:

performing a third finishing operation on a first subset of the first portion of the plurality of RMC samples and a first subset of the second portion of the plurality of RMC samples to alter the surface finish properties of the first subsets of RMC samples; and

performing a fourth finishing operation on a second subset of the first portion of the plurality of RMC samples and a second subset of the second portion of the plurality of RMC samples to alter the surface finish properties of the second subsets of RMC samples.

12. The method as recited in claim 9 , wherein the step of performing the validation operations includes:

pull testing a first portion of the plurality of RMC samples to assess coating adhesion;

furnace testing a second portion of the plurality of RMC samples to assess coating adhesion; or

casting a third portion of the plurality of RMC samples to assess casting defects.

13. The method as recited in claim 9 , wherein the plurality of finishing operations include at least harperizing, robotic machining and etching.

14. A refractory metal core (RMC) finishing method, the method comprising:

measuring at least one property of a plurality of RMC samples;

splitting the plurality of RMC samples into at least two portions;

harperizing one of the at least two portions for a first amount of time;

harperizing the other of the at least two portions for a second amount of time different from the first amount of time;

after the harperizing steps, measuring the at least one property of the plurality of RMC samples;

coating the plurality of RMC samples; and

performing at least one validation operation on the plurality of RMC samples,

wherein the measuring at least one property of a plurality of RMC samples includes measuring the sharpness of break edges and the surface finish of the plurality of RMC samples.

15. The method as recited in claim 14 , wherein the at least one validation operation includes at least one of furnace testing and casting.

16. The method as recited in claim 14 , wherein the splitting the plurality of RMC samples into at least two portions includes splitting the plurality of RMC samples into three portions.

17. The method as recited in claim 16 , the method comprising:

robotic machining a third portion of the three portions.