Ceramic cores for casting superalloys and refractory metal composites, and related processes

摘要

A rare earth-based core for use in the casting of a reactive metal is described. The core contains a ceramic composition which includes at least about 10% by weight of monoclinic rare earth aluminate (RE₄Al₂O₉), wherein RE represents at least one rare earth element; and at least about 10% by weight of at least one free rare earth oxide. The ceramic phase of the composition may include a microstructure which comprises a multitude of substantially spherical pores which are formed as a result of the removal of aluminum metal from the core composition during a heat treatment step. Additional embodiments relate to a method for the fabrication of a ceramic core, employing a rare earth oxide, aluminum metal, and a binder. Methods for removing cores from a cast part are also described.