Casting core assembly methods

1. A process for forming a casting core assembly, the assembly comprising a metallic core and a ceramic core, the process comprising:

inserting a ceramic plug of the metallic core into a compartment in the ceramic core; and

securing the ceramic plug to the ceramic core.

2. The process of claim 1 wherein:

the securing comprises introducing a ceramic adhesive between the plug and compartment.

3. The process of claim 1 further comprising:

shaping the metallic core; and

applying an aluminide coating to the shaped metallic core.

4. The process of claim 1 further comprising:

molding the ceramic plug to the metallic core.

5. The process of claim 4 further comprising:

masking the metallic core to mask wicking of ceramic during the molding.

6. The process of claim 4 further comprising:

molding the ceramic core at a higher temperature than the molding of the ceramic plug.

7. The process of claim 4 wherein further comprising:

molding a sacrificial layer to the metallic core in a first die, and

wherein the molding of the plug comprises:

transferring the metallic core and sacrificial layer to a second die; and

introducing a ceramic-forming material to a plug-forming compartment of the second die.

8. The process of claim 7 wherein the molding of the sacrificial layer comprises:

applying at least one pre-formed sacrificial member to the metallic core; and

cold molding the sacrificial layer from the pre-formed sacrificial member in the first die.

9. The process of claim 7 wherein the molding of the sacrificial layer comprises:

applying a first wax sheet to a first face of the metallic core;

applying a second wax sheet to a second face of the metallic core; and

cold molding the sacrificial layer from the wax sheets in the first die.

10. The process of claim 7 further comprising:

heating to remove the sacrificial layer and harden the ceramic-forming material.

11. The process of claim 7 being a portion of a pattern-forming process and further comprising:

removing the sacrificial layer; and

hardening the ceramic-forming material,

the pattern-forming process further comprising:

applying a further sacrificial member to the metallic core;

overmolding a main pattern-forming material to the core assembly in a pattern-forming die, the further sacrificial member maintaining a position of the metallic core in the pattern-forming die.

12. The process of claim 11 being a portion of a shell-forming process, the shell-forming process further comprising:

shelling the pattern; and

removing the further sacrificial material and main pattern-forming material and hardening the shell.

13. The process of claim 12 being a portion of a casting process, the casting process further comprising:

introducing molten metal to the shell;

allowing the metal to solidify;

destructively removing the shell and the core assembly.

14. The process of claim 1 wherein:

the ceramic core forms a feed passageway in an airfoil; and

the metallic core forms an outlet passageway from the feed passageway to a pressure side or a suction side of the airfoil.

15. The process of claim 1 further comprising:

placing first and second wax sheets on respective first and second sides of the metallic casting core;

cold forming the sheets while on the metallic casting core in a cold wax die to form a contour;

placing the metallic casting core and formed first and second sheets into a plug die; and

introducing a ceramic-forming material to the plug die to form the ceramic plug.

16. A casting core assembly comprising:

a metallic core;

a ceramic plug in which a portion of the metallic core is embedded;

a ceramic core having a compartment in which the plug is received; and

a ceramic adhesive joint between the plug and the ceramic core.

17. The assembly of claim 16 wherein:

the ceramic core is an airfoil feedcore; and

the metallic core is an outlet core.