Ceramic cores for turbine blades via injection moulding

• Whole manufacturing technology for ceramic cores fabrication was presented.
• Technology satisfies all requirements for high precision blades fabrication.
• Cores were positively verified in industrial conditions during blade casting.
• Technology, because of its efficiency, can be applied at industrial scale.

The proposed injection moulding method to produce ceramic cores of turbine blades required the selection of raw materials and the thermoplasticiser as well as the determination of the optimal processing conditions. The selected material enabled the formation of cores with a small cross-section area and was characterised by low shrinkage as well as a relatively low coefficient of thermal expansion. The high mechanical strength of the material allowed for the cores to be formed in a wax model and their assembly in a foundry mould; in addition, the appropriate porosity of the cores ensured their easy etching by means of a water solution of bases. The cores were characterised by high dimensional precision and negligibly small shape deformation. The usability of the cores was positively verified in the process of turbine blades casting in production conditions.