Segmented Turbine Blade Core for Casting Complex Cooling Passages

The core is divided into multiple separate core units, each forming a specific cooling passage. The core units are inserted into the mold separately and positioned using guide structures, allowing each unit to be simpler in shape while collectively forming the complex cooling passage system. This segmentation prevents breakage during separation while achieving the required cooling passage complexity.

Guide structures are introduced as intermediary elements between the core units and the mold. These guide structures include guide grooves in the mold and corresponding guide protrusions on the core units, which facilitate easy positioning and insertion of the core units while simplifying the manufacturing process. The guide structures mediate the interaction between the complex multi-unit core and the mold, making assembly and separation straightforward despite the increased core structural complexity.

The core units are designed with asymmetric features including guide protrusions that match corresponding guide grooves in the mold. This asymmetric design ensures that each core unit can only be inserted in the correct orientation, automatically achieving proper positioning. The streamlined cross-section of the cooling passages is maintained while the asymmetric guide features simplify the operation of inserting and positioning the core units during manufacturing.