A casting core assembly (140) includes a metallic core (144, 146, 148), a ceramic core (142) having a compartment (186) in which the portion of the metallic core is received, and a ceramic coating (260) at least partially covering the metallic core and the ceramic core.

A ceramic resin is provided, along with its methods of formation and use. The ceramic resin may include a crosslinkable precursor, a photoinitiator, ceramic particles, and pore forming particles. The ceramic resin may be utilized to form a ceramic casting element, such as via a method that includes forming a layer of the ceramic resin; applying light onto the ceramic resin such that the photoinitiator initiates polymerization of the crosslinkable precursor to form a crosslinked polymeric matrix setting the ceramic particles and the pore forming particles; and thereafter, heating the crosslinked polymeric matrix to a first temperature to burn out the pore forming particles.

A casting core may include a core body and a tip comb extending from a tip region of the core body. The tip comb may be integrally formed with the core body. The tip comb may comprise a first casting pedestal and a second casting pedestal. The first casting pedestal and the second casting pedestal may define an aperture having a tapered geometry.

The casting material may be formed around the casting core using a variety of conventional casting techniques including direct liquid metal infiltration, pressure assisted casting, and centrifugal casting among others.

A ceramic resin is provided, along with its methods of formation and use. The ceramic resin may include a crosslinkable precursor, a photoinitiator, ceramic particles, and pore forming particles. The ceramic resin may be utilized to form a ceramic casting element, such as via a method that includes forming a layer of the ceramic resin; applying light onto the ceramic resin such that the photoinitiator initiates polymerization of the crosslinkable precursor to form a crosslinked polymeric matrix setting the ceramic particles and the pore forming particles; and thereafter, heating the crosslinked polymeric matrix to a first temperature to burn out the pore forming particles.

A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from a first material, and an inner core formed from an inner core material disposed within the hollow structure. The method also includes 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 first material from a portion of the jacketed core within the cavity. The method further includes cooling the component material in the cavity to form the component, and removing the inner core material from the component to form the internal passage.

A method of forming an airfoil (12), including: abutting end faces (72) of cantilevered film hole protrusions (64) extending from a ceramic core (50) against an inner surface (80) of a wax die (68) to hold the ceramic core in a fixed positional relationship with the wax die; casting an airfoil including a superalloy around the ceramic core; and machining film cooling holes (34) in the airfoil after the casting step to form an pattern of film cooling holes comprising the film cooling holes formed by the machining step and the cast film cooling holes (102) formed by the film hole protrusions during the casting step.

An exemplary forming assembly includes a mold having a cavity to form a component, and an insert having first, second, and third regions. The first region provides a first passageway opening in the component. The second region provides a second passageway opening in the component. The third region provides a passageway in the component. The insert is rotatable from a first position within the passageway to a second position outside the passageway. An exemplary component forming method includes positioning a material around an insert, curing the material to provide a component, and rotating the insert relative to the component from a first position where at least some of the insert is received within a passageway of the component to a second position where the entire insert is outside the passageway.

A method for producing iron metal castings, wherein an expendable mold having a cavity for holding casting material is inserted into an opened multi-part permanent mold, the permanent mold is closed, the cavity is filled with casting material, wherein a supporting device partially protruding into the cavity is partially overcast, the expendable mold is cooled in the permanent mold after the filling, the permanent mold is opened during the cooling, after the liquidus temperature has been fallen below at the earliest, and the expendable mold is nondestructively removed from the permanent mold together with the casting, the expendable mold is further cooled together with the solidified casting while hanging on the supporting device, at least until the microstructure formation of the casting is concluded, the casting is demolded by removing the expendable mold.

A caliper includes a hydraulic linking channel provided in a bridge section linking hydraulic cylinders, on an inner caliper section side, and hydraulic cylinders, on an outer caliper section side, to a cylinder-side hydraulic channel disposed on the back end of each respectively. A connecting channel forming section, which corresponds to each cylinder-side hydraulic channel and the hydraulic linking channel is provided, in advance, in a core used during casting of the inner caliper section, the outer caliper section, and the bridge section, and is formed by setting in a situation to be embedded at the same time as each caliper section and the bridge section are being integrally cast.