Method for removing a magnesia doped alumina core material

Claim 1

A method for removing a ceramic core material comprising magnesia doped alumina disposed in an abutting relationship of a casting of an advanced superalloy material, wherein the composition of the ceramic material includes a magnesia content of greater than about 1 mole percent but no greater than about 20 mole percent, balance alumina, and the microstructure of the magnesia doped alumina is characterized by a matrix comprising an interconnecting network of magnesia doped alumina defining a plurality of interstices in which the material magnesium aluminate spinel is deposited, comprising the process steps of (a) placing the casting and the ceramic core material in an autoclave containing a leaching solution selected from the group consisting of a solution of NaOH and a solution of KOH said leaching solution being from about 10 percent by weight to about 70 weight hydroxide and the balance water; (b) heating the casting, ceramic core material and leaching solution to a temperature of at least about 200° C; (c) dissolving substantially all of the magnesia doped alumina interconnecting network in the ceramic core material by chemical attack by the leaching solution, and (d) removing at least some of the undissolved ceramic core material from the casting by the solution agitated by the chemical reaction.

Claim 2

A method for removing a ceramic core material comprising magnesia doped alumina disposed in an abutting relationship of a casting of an advanced superalloy material, wherein the composition of the ceramic material includes a magnesia content of greater than about 1 mole percent but no greater than about 20 mole percent, balance alumina, and the microstructure of the magnesia doped alumina is characterized by a matrix comprising an interconnecting network of magnesia doped alumina defining a plurality of interstices in which the material magnesium aluminate spinel is deposited, comprising the process steps of (a) placing the casting and the ceramic core material in an autoclave containing a leaching solution selected from the group consisting of a solution of NaOH and a solution of KOH said leaching solution being from about 10 percent by weight to about 70 weight hydroxide and the balance water; (b) heating the casting, ceramic core material and leaching solution to a temperature of at least about 200° C; (c) dissolving substantially all of the magnesia doped alumina interconnecting network in the ceramic core material by chemical attack by the leaching solution, and (d) removing at least some of the undissolved ceramic core material from the casting by the solution agitated by the chemical reaction.