Casting core post and socket joint
A casting core assembly has: a first ceramic piece including a projecting post; a second ceramic piece including a socket encircling the post; and a ceramic filler material between the post and the socket. At least one of: in axial section at at least one location the post has a lateral protrusion of at least 15 micrometers relative to a location proximal thereof; and in axial section at at least one location socket has a lateral recess of at least 15 micrometers relative to a location outboard thereof.
1 . A casting core assembly comprising:
a first ceramic piece including an integrally molded projecting post;
a second ceramic piece including a socket encircling the post; and
a ceramic filler material between the post and the socket,
wherein at least one of:
in axial section at at least one location the post has:
a lateral protrusion of at least 15 micrometers relative to a location proximal thereof; and
in axial section at at least one location the socket has:
a lateral recess of at least 15 micrometers relative to a location outboard thereof.
2 . The casting core assembly of claim 1 wherein:
the socket is a closed-ended socket.
3 . The casting core assembly of claim 1 wherein at least one of:
the protrusion is full annulus; and
the recess is full annulus.
4 . The apparatus of claim 1 wherein both of:
the post has said lateral protrusion; and
the socket has said lateral recess.
5 . The casting core assembly of claim 4 wherein:
the protrusion is full annulus; and
the recess is full annulus.
6 . The casting core assembly of claim 4 wherein:
the protrusion has an outward extreme; and
the recess has an outward extreme axially outboard of the protrusion outward extreme.
7 . The casting core assembly of claim 4 wherein:
the protrusion is formed as a distal wall section of a full annulus recess in the post, a proximal wall section also being in the socket; and
the recess is full annulus.
8 . The casting core assembly of claim 1 and further comprising:
a second said post and a second said socket and a ceramic filler material between the second post and the second socket.
9 . The casting core assembly of claim 1 wherein:
the protrusion forms a distal wall of a post recess; and
the recess is recessed relative to portions of the socket inward and outward thereof.
10 . The casting core assembly of claim 1 wherein:
a separation Ho between the first ceramic piece and the second ceramic piece aside the projection and the socket is 0.35 mm to 2.0 mm.
11 . The casting core assembly of claim 1 wherein:
in transverse section at at least one further location one of the post and the socket has a configuration of:
three circumferentially offset radial peaks of a peak radius (R PMAX1 , R SMAX1 ); and
three radial troughs of a trough radius (R PMIN1 , R SMIN1 ) not more than 98.0% of the peak radius.
12 . The casting core assembly of claim 1 wherein:
the second ceramic piece forms a feedcore; and
the first ceramic piece forms a skin core.
13 . The casting core assembly of claim 1 wherein:
the first ceramic piece has one or more bumpers protruding to contact the second ceramic piece.
14 . A method for manufacturing the casting core assembly of claim 1 , the method comprising:
introducing a ceramic paste into the socket; and
inserting the post into the socket, the inserting displacing the ceramic paste, the ceramic paste hardening to form the ceramic filler material.
15 . The method of claim 14 further comprising forming the second ceramic piece by:
molding; and
machining the socket, the machining including an orbit of a ball mill cutting the recess.
16 . The method of claim 15 wherein:
the ball mill cutting is into a wall surface formed by ball end mill cutting with a different bit.
17 . A method for using the casting core assembly of claim 1 , the method comprising:
wax overmolding;
shelling to form a shell; and
casting an alloy in the shell.
18 . The method of claim 17 further comprising:
deshelling and decoring.
19 . A casting core assembly comprising:
a first ceramic piece including an integrally molded projecting post;
a second ceramic piece including a socket encircling the post; and
a ceramic filler material between the post and the socket,
wherein at least one of the post and the socket has a full annular recess into which the ceramic filler material extends to axially backlock said at least one to the ceramic filler material.
20 . A casting core assembly comprising:
a first ceramic piece including an integrally molded projecting post;
a second ceramic piece including a socket having an axis; and
a ceramic filler material between the post and the socket,
wherein the ceramic filler is axially backlocked to the post and the socket to prevent nondestructive axial extraction of the post from the socket.
21 . The casting core assembly of claim 20 wherein:
the ceramic filler is axially backlocked to the post and the socket by at least 10 micrometers.
22 . The casting core assembly of claim 20 wherein:
each of the post and the socket has a full annular recess into which the ceramic filler material extends.