METHOD INCLUDING FIBER REINFORCED CASTING ARTICLE
A method of forming an engine component according to an exemplary aspect of the present disclosure includes, among other things, introducing molten metal into a cavity between a shell and a casting article in the shell. The casting article includes a ceramic portion and a plurality of fibers. The method further includes separately removing the ceramic portion and the fibers from an interior of the component.
1 . A method of forming an engine component, comprising:
introducing molten metal into a cavity between a shell and a casting article in the shell, the casting article including a ceramic portion and a plurality of fibers; and
separately removing the ceramic portion and the fibers from an interior of the component.
2 . The method as recited in claim 1 , further comprising:
cooling the molten metal, wherein the plurality of fibers and the ceramic portion are removed after the molten metal cools.
3 . The method as recited in claim 2 , wherein the ceramic portion is removed from the component using a leaching fluid, and the fibers are mechanically removed from the component.
4 . The method as recited in claim 3 , wherein the fibers are blown out of the component using a pressurized fluid.
5 . The method as recited in claim 4 , wherein the pressurized fluid is pressurized air.
6 . The method as recited in claim 4 , wherein a maximum length of the fibers is less than a smallest orifice formed in the engine component.
7 . The method as recited in claim 1 , wherein the fibers dissolve during the introducing step.
8 . The method as recited in claim 7 , wherein the fibers fully dissolve during the introducing step.
9 . The method as recited in claim 7 , wherein, after the molten metal cools, the remainder of the casting article is removed from the component using a leaching fluid.
10 . The method as recited in claim 7 , wherein the size and chemical composition of the fibers is selected such that the fibers will intentionally dissolve during the introducing step.
11 . The method as recited in claim 1 , wherein the fibers are randomly oriented within the ceramic portion.
12 . The method as recited in claim 11 , wherein the ceramic portion includes alumina (Al 2 O 3 ).
13 . The method as recited in claim 1 , wherein the fibers are provided by one of (1) silicon (Si) fibers, (2) carbon (C) fibers, and (3) metal fibers.
14 . A method of forming an engine component, comprising:
introducing molten metal into a cavity between a shell and a casting article, the casting article including a ceramic portion and a plurality of fibers;
dissolving the fibers during the introducing step; and
removing the remainder of the casting article from the interior of the component using a leaching fluid.
15 . The method as recited in claim 14 , wherein the size and material of the fibers is selected such that the fibers will intentionally dissolve during the introducing step.
16 . The method as recited in claim 14 , wherein the fibers completely dissolve during the introducing step.
17 . The method as recited in claim 14 , wherein the ceramic portion includes alumina (Al 2 O 3 ).
18 . The method as recited in claim 14 , wherein the fibers are provided by one of (1) silicon (Si) fibers, (2) carbon (C) fibers, and (3) metal fibers.
19 . A method of forming an engine component, comprising:
providing a ceramic shell and a casting article, the casting article including a ceramic portion and a plurality of fibers;
sintering the ceramic shell and the casting article, wherein the plurality of fibers are dissolved by the sintering step;
introducing a molten metal between the shell and the casting article; and
removing the remainder of the casting article from the interior of the component.