Method and assembly for forming components having internal passages using a jacketed core

1. A method of forming a component having an internal passage defined therein, said method comprising:

forming a precursor core having a shape corresponding to a shape of the internal passage;

forming a hollow structure of a first material around an outer wall of the precursor core, wherein the first material is metallic;

removing the precursor core from within the hollow structure;

subsequent to removal of the precursor core, disposing an inner core within the hollow structure such that the hollow structure and the inner core form a jacketed core;

positioning the jacketed core with respect to a mold;

introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the hollow structure from a portion of the jacketed core within the cavity; and

cooling the component material in the cavity to form the component, wherein the inner core defines the internal passage within the component.

2. The method of claim 1 , wherein forming the hollow structure around the outer wall of the precursor core comprises complementarily shaping an interior portion of the hollow structure by the outer wall of the precursor core.

3. The method of claim 1 , wherein disposing the inner core within the hollow structure comprises complementarily shaping the inner core by an interior portion of the hollow structure, such that the inner core has a shape corresponding to the shape of the internal passage.

4. The method of claim 1 , wherein forming the precursor core comprises forming the precursor core at least partially using an additive manufacturing process.

5. The method of claim 4 , wherein forming the precursor core comprises forming the precursor core using a stereolithographic process.

6. The method of claim 4 , wherein forming the precursor core comprises forming the precursor core using at least one of a fused filament fabrication process, an inkjet/powder bed process, a selective heat sintering process, and a selective laser sintering process.

7. The method of claim 1 , wherein forming the precursor core comprises forming the precursor core from a photopolymer material.

8. The method of claim 1 , wherein forming the precursor core comprises forming the precursor core from a thermoplastic material.

9. The method of claim 1 , wherein removing the precursor core from within the hollow structure comprises melting the precursor core.

10. The method of claim 1 , wherein removing the precursor core from within the hollow structure comprises machining the precursor core out of the hollow structure.

11. The method of claim 1 , wherein removing the precursor core from within the hollow structure comprises removing the precursor core from the hollow structure using a chemical removal process.

12. The method of claim 1 , wherein forming the hollow structure around the outer wall of the precursor core comprises depositing the first material around the outer wall in a plating process.

13. The method of claim 12 , wherein forming the hollow structure around the outer wall of the precursor core comprises depositing the first material around the outer wall in a metal plating process.

14. The method of claim 13 , wherein forming the hollow structure around the outer wall of the precursor core comprises depositing the first material around the outer wall in an electroless plating process.

15. The method of claim 13 , wherein forming the hollow structure around the outer wall of the precursor core comprises depositing the first material around the outer wall in an electroplating process.

16. The method of claim 12 , wherein forming the hollow structure around the outer wall of the precursor core comprises depositing a plurality of materials from an interior portion of the hollow structure to an outer wall of the hollow structure in successive layers.

17. The method of claim 16 , wherein depositing a plurality of materials comprises:

depositing a first metal alloy around the outer wall of the precursor core as an initial layer of the plurality of layers using an electroless plating process; and

depositing a second metal alloy as a subsequent layer of the plurality of layers using an electroplating process.

18. The method of claim 1 , wherein disposing the inner core within the hollow structure comprises:

injecting an inner core material as a slurry into the hollow structure; and

drying the inner core material within the hollow structure to form the inner core.

19. The method of claim 1 , wherein the internal passage includes at least one passage wall feature, and forming the precursor core comprises forming at least one complementary feature of the precursor core such that the at least one complementary feature has a shape complementary to a shape of the at least one passage wall feature.

20. The method of claim 19 , wherein the at least one passage wall feature is a ridge extending interiorly from an interior wall of the component, and forming the at least one complementary feature of the precursor core comprises forming a plurality of recessed features along the outer wall of the precursor core.

21. The method of claim 1 , wherein forming the precursor core comprises shaping the precursor core to define a cross-sectional shape of the internal passage that conforms to a geometry of the component.

22. The method of claim 1 , further comprising removing the inner core from the component to form the internal passage within the component.