Abstract:
A core assembly includes a core that includes an exterior surface that has a recessed area that extends along the exterior surface. An insert includes a contact surface that corresponds to the recessed area.

Description:
BACKGROUND 
       [0001]    A gas turbine engine typically includes a fan section, a compressor section, a combustor section, and a turbine section. Air entering the compressor section is compressed and delivered into the combustion section where it is mixed with fuel and ignited to generate a high-speed exhaust gas flow. The high-speed exhaust gas flow expands through the turbine section to drive the compressor and the fan section. 
         [0002]    Turbine engine components, such as turbine blades and vanes, are operated in high temperature environments. To avoid deterioration in the components resulting from their exposure to high temperatures, it is necessary to provide cooling circuits within the components. Turbine blades and vanes are subjected to high thermal loads on both the suction and pressure sides of their airfoil portions and at both the leading and trailing edges. The regions of the airfoils having the highest thermal load can differ depending on engine design and specific operating conditions. 
         [0003]    Minicore technology offers the potential to provide higher specific cooling passages for turbine components such as blade and vane airfoils, blade outer air seals (BOAS) and combustor or gas path panels. Minicore technology utilizes refractory metal cores to allow cooling circuits to be placed just under the surface of the hot wall through which cooling air flows and is expelled into the gas path. However, state of the art cooling circuits made using refractory metal cores can contain artifacts in the event of incomplete removal of adhesive material prior to casting. These defects and artifacts can reduce the cooling effectiveness provided by the cooling circuits and compromise the strength of the component. 
       SUMMARY 
       [0004]    In one exemplary embodiment, a core assembly includes a core that includes an exterior surface that has a recessed area that extends along the exterior surface. An insert includes a contact surface that corresponds to the recessed area. 
         [0005]    In a further embodiment of the above, the core includes an upstream end and a downstream end. A first side extends between the upstream end and downstream end. A second side extends between the upstream end and the downstream end. 
         [0006]    In a further embodiment of any of the above, the insert is a refractory metal core that includes a first end, a second end, a first side, and a second side. 
         [0007]    In a further embodiment of any of the above, the contact surface is located on the first side of the refractory metal core. 
         [0008]    In a further embodiment of any of the above, the recessed area is located on at least one of the first side and the second side of the core. The first end of the refractory metal core is located adjacent the downstream end of the core. 
         [0009]    In a further embodiment of any of the above, a tab extends from the first side of the refractory metal core. 
         [0010]    In a further embodiment of any of the above, the tab extends to the upstream end of the core and the recessed area extends from the upstream end to the downstream end. 
         [0011]    In a further embodiment of any of the above, the recessed area includes a slot for accepting the tab. 
         [0012]    In a further embodiment of any of the above, the recessed area extends at least partially along the first side, the downstream end, and the second side. The contact surface abuts to the recessed area along the first side, the downstream end, and the second side. 
         [0013]    In a further embodiment of any of the above, the refractory metal core includes a first tab that extends along the first side of the recessed area and a second tab that extends along the second side of the recessed area. 
         [0014]    In a further embodiment of any of the above, a leading edge core has an upstream end, a downstream end, a first side, and a second side. A first recessed area is on the first side and the second side of the core. A second recessed area is on the first side, the upstream end, and the second side of the leading edge core. The refractory metal core abuts the first recessed area and the second recessed area. 
         [0015]    In a further embodiment of any of the above, the insert includes at least one bend. 
         [0016]    In a further embodiment of any of the above, the insert is secured within the recessed area with an adhesive. 
         [0017]    In a further embodiment of any of the above, a component for a gas turbine engine is made from the core assembly of claim  1 . 
         [0018]    In another exemplary embodiment, a method of forming a core assembly includes forming a recessed area along an exterior surface of a core. A refractory metal core having a first end, a second end, a first side, and a second side is positioned into the recessed area such that the first side includes a contact surface adjacent the recessed area and the first end and the second end are spaced from the recessed area. 
         [0019]    In a further embodiment of any of the above, the core includes an upstream end, a downstream end, a first side that extends between the upstream end and downstream end and a second side that extends between the upstream end and the downstream end. 
         [0020]    In a further embodiment of any of the above, the recessed area is located on at least one of the first side of the core. The first end of the refractory metal core is located adjacent the downstream end of the core. 
         [0021]    In a further embodiment of any of the above, a tab is aligned on the refractory metal core and a corresponding slot in the recessed area. 
         [0022]    In a further embodiment of any of the above, the tab extends to the upstream end of the core and the recessed area extends from the upstream end to the downstream end of the core. 
         [0023]    In a further embodiment of any of the above, the recessed area extends along the first side, the downstream end, and the second side of the core. The contact surface on the refractory metal core abuts the recessed area along the first side, the downstream end, and the second side. 
         [0024]    In a further embodiment of any of the above, the refractory metal core includes a first tab that extends along the first side of the recessed area and a second tab that extends along the second side of the recessed area. 
         [0025]    In a further embodiment of any of the above, a leading edge core has an upstream end, a downstream end, a first side, and a second side. A first recessed area is on the first side and the second side of the core. A second recessed area is on the pressure side, the upstream end, and the second side of the leading edge core. The refractory metal core extends between the first recessed area and the second recessed area. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0026]      FIG. 1  is a schematic view of an example gas turbine engine. 
           [0027]      FIG. 2  shows an example gas turbine engine component. 
           [0028]      FIG. 3  is a cross-sectional view taken along line  3 - 3  of  FIG. 2 . 
           [0029]      FIG. 4  is perspective view of an example ceramic core assembly. 
           [0030]      FIG. 5  is a cross-sectional view taken along line  5 - 5  of  FIG. 4 . 
           [0031]      FIG. 6  is an enlarged view of  FIG. 5 . 
           [0032]      FIG. 7  is a cross-sectional view of another example ceramic core assembly. 
           [0033]      FIG. 8  is a cross-sectional view of yet another example ceramic core assembly. 
           [0034]      FIG. 9  is a cross-sectional view of a further example ceramic core assembly. 
           [0035]      FIG. 10  is a cross-sectional view of a further example ceramic core assembly. 
           [0036]      FIG. 11  is a cross-sectional view of a further example ceramic core assembly. 
           [0037]      FIG. 12  is a cross-sectional view of a further example ceramic core assembly. 
           [0038]      FIG. 13  is a cross-sectional view of a further example ceramic core assembly. 
           [0039]      FIG. 14  is a cross-sectional view of a further example ceramic core assembly. 
           [0040]      FIG. 15  is a cross-sectional view of a cast component from the ceramic core assembly of  FIG. 14 . 
       
    
    
     DETAILED DESCRIPTION 
       [0041]      FIG. 1  schematically illustrates a gas turbine engine  20 . The gas turbine engine  20  is disclosed herein as a two-spool turbofan that generally incorporates a fan section  22 , a compressor section  24 , a combustor section  26  and a turbine section  28 . Alternative engines might include an augmentor section (not shown) among other systems or features. The fan section  22  drives air along a bypass flow path B in a bypass duct defined within a nacelle  15 , while the compressor section  24  drives air along a core flow path C for compression and communication into the combustor section  26  then expansion through the turbine section  28 . Although depicted as a two-spool turbofan gas turbine engine in the disclosed non-limiting embodiment, it should be understood that the concepts described herein are not limited to use with two-spool turbofans as the teachings may be applied to other types of turbine engines including three-spool architectures. 
         [0042]    The exemplary engine  20  generally includes a low speed spool  30  and a high speed spool  32  mounted for rotation about an engine central longitudinal axis A relative to an engine static structure  36  via several bearing systems  38 . It should be understood that various bearing systems  38  at various locations may alternatively or additionally be provided, and the location of bearing systems  38  may be varied as appropriate to the application. 
         [0043]    The low speed spool  30  generally includes an inner shaft  40  that interconnects a fan  42 , a first (or low) pressure compressor  44  and a first (or low) pressure turbine  46 . The inner shaft  40  is connected to the fan  42  through a speed change mechanism, which in exemplary gas turbine engine  20  is illustrated as a geared architecture  48  to drive the fan  42  at a lower speed than the low speed spool  30 . The high speed spool  32  includes an outer shaft  50  that interconnects a second (or high) pressure compressor  52  and a second (or high) pressure turbine  54 . A combustor  56  is arranged in exemplary gas turbine  20  between the high pressure compressor  52  and the high pressure turbine  54 . A mid-turbine frame  57  of the engine static structure  36  is arranged generally between the high pressure turbine  54  and the low pressure turbine  46 . The mid-turbine frame  57  further supports bearing systems  38  in the turbine section  28 . The inner shaft  40  and the outer shaft  50  are concentric and rotate via bearing systems  38  about the engine central longitudinal axis A which is collinear with their longitudinal axes. 
         [0044]    The core airflow is compressed by the low pressure compressor  44  then the high pressure compressor  52 , mixed and burned with fuel in the combustor  56 , then expanded over the high pressure turbine  54  and low pressure turbine  46 . The mid-turbine frame  57  includes airfoils  59  which are in the core airflow path C. The turbines  46 ,  54  rotationally drive the respective low speed spool  30  and high speed spool  32  in response to the expansion. It will be appreciated that each of the positions of the fan section  22 , compressor section  24 , combustor section  26 , turbine section  28 , and fan drive gear system  48  may be varied. For example, gear system  48  may be located aft of combustor section  26  or even aft of turbine section  28 , and fan section  22  may be positioned forward or aft of the location of gear system  48 . 
         [0045]    The engine  20  in one example is a high-bypass geared aircraft engine. In a further example, the engine  20  bypass ratio is greater than about six (6), with an example embodiment being greater than about ten (10), the geared architecture  48  is an epicyclic gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3 and the low pressure turbine  46  has a pressure ratio that is greater than about five. In one disclosed embodiment, the engine  20  bypass ratio is greater than about ten (10:1), the fan diameter is significantly larger than that of the low pressure compressor  44 , and the low pressure turbine  46  has a pressure ratio that is greater than about five 5:1. Low pressure turbine  46  pressure ratio is pressure measured prior to inlet of low pressure turbine  46  as related to the pressure at the outlet of the low pressure turbine  46  prior to an exhaust nozzle. The geared architecture  48  may be an epicycle gear train, such as a planetary gear system or other gear system, with a gear reduction ratio of greater than about 2.3:1. It should be understood, however, that the above parameters are only exemplary of one embodiment of a geared architecture engine and that the present invention is applicable to other gas turbine engines including direct drive turbofans. 
         [0046]    A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section  22  of the engine  20  is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet. The flight condition of 0.8 Mach and 35,000 ft (10,668 meters), with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (&#39;TSFC&#39;)”—is the industry standard parameter of lbm of fuel being burned divided by lbf of thrust the engine produces at that minimum point. “Low fan pressure ratio” is the pressure ratio across the fan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.45. “Low corrected fan tip speed” is the actual fan tip speed in ft/sec divided by an industry standard temperature correction of [(Tram ° R)/(518.7° R)] 0.5 . The “Low corrected fan tip speed” as disclosed herein according to one non-limiting embodiment is less than about 1150 ft/second (350.5 meters/second). 
         [0047]    The example gas turbine engine includes fan  42  that comprises in one non-limiting embodiment less than about twenty-six (26) fan blades. In another non-limiting embodiment, fan section  22  includes less than about twenty (20) fan blades. Moreover, in one disclosed embodiment low pressure turbine  46  includes no more than about six (6) turbine rotors schematically indicated at  34 . In another non-limiting example embodiment low pressure turbine  46  includes about three (3) turbine rotors. A ratio between number of fan blades  42  and the number of low pressure turbine rotors is between about 3.3 and about 8.6. The example low pressure turbine  46  provides the driving power to rotate fan section  22  and therefore the relationship between the number of turbine rotors  34  in low pressure turbine  46  and number of blades  42  in fan section  22  disclose an example gas turbine engine  20  with increased power transfer efficiency. 
         [0048]      FIG. 2  illustrates an example gas turbine engine component  60 . In the illustrated example, the component  60  includes an airfoil  62 , a platform  64 , and optionally a root portion  66 . In the illustrated example, the component  60  is a turbine blade. However, the component  60  could also be a vane, a compressor blade, a combustor liner, a blade outer air seal, or any structure that with cooling features formed from ceramic cores or core of other material. The component  60  is configured to form a circumferential ring surrounding the engine axis A when jointed with additional similar components  60 . In this disclosure, circumferential or circumferentially spaced is relative to a circumference surrounding the engine axis A of the gas turbine engine  20  unless otherwise specified. 
         [0049]    The radially outer side  70  of the platform  64  forms a radially inner boundary for fluid traveling over the component  60 . The root portion  66  extends radially inward from the platform  64  to retain the component  60  to a turbine rotor  79  ( FIG. 1 ). The root portion  66  is located on an opposite side of the platform  64  from the airfoil  62  on a radially inner side  83 . The root portion  66  includes teeth  67  located on opposite sides of the root portion  66  for engaging complimentary shaped receptacles on the turbine rotor  79  of the gas turbine engine  20 . 
         [0050]    As shown in  FIG. 2 , a first plurality of cooling holes  80  are spaced radially along a leading edge  76  of the airfoil  62  on both a pressure side  72  and a suction side  74 . Although the cooling holes  80  in the illustrated example are circular, other shapes such as elliptical holes, oval holes, oblong holes, and race-track shaped holes could be used. 
         [0051]    A plurality of cooling slots  84  are spaced radially along the pressure side  72  of the airfoil  62 . In the illustrated example, the plurality of cooling slots  84  is axially aligned and extends in a radial direction. However, the plurality of cooling slots  84  could be axially spaced from each other. 
         [0052]    A plurality of trailing edge cooling holes  86  are spaced radially along the pressure side  72  of the airfoil  62  immediately upstream of a trailing edge  78 . 
         [0053]    As shown in  FIG. 3 , the airfoil  62  includes internal cooling passages, such as a leading edge cooling passage  88 , an intermediate cooling passage  90 , and a trailing edge cooling passage  92 . In the illustrated example, the intermediate cooling passage  90  feeds cooling airflow to the plurality of cooling slots  84  to create a cooling film over the pressure side  72  as the cooling airflow travels out of the plurality of cooling slots  84  and towards the trailing edge  78 . However, the plurality of cooling slots  84  could be fed from either the leading edge cooling passage  88  or the trailing edge cooling passage  92 . 
         [0054]    The plurality of cooling slots  84  are each fed by a slot passage  94  forming an internal cooling circuit  96  (a network of cooling passages). The slot passage  94  for the cooling slot  84  is formed by an investment casting process. In one example investment casting process, ceramic cores are used to form the leading edge cooling passage  88 , an intermediate cooling passage  90 , and a trailing edge cooling passage  92 . Inserts, such as a refractory metal core (RMC), can be used to form the internal cooling circuits  96  for receiving cooling airflow from the cooling passages  88 ,  90 , and  92  formed by the ceramic core elements. 
         [0055]    In one investment casting method, the ceramic feed core and the RMC are formed separately. The RMC is then secured to the ceramic feed core, typically using a ceramic adhesive or glue. A wax pattern is formed over the RMC and ceramic feed cores, which form a core assembly. A ceramic shell is then formed over the wax pattern and the wax pattern is removed from the shell. Molten metal is introduced into the ceramic shell. The molten metal, upon cooling, solidifies and forms the component  60 . The ceramic feed cores form the cooling passages  88 ,  90 , and  92  in the component  60  and the RMC at least partially defines the internal cooling circuit  96 . The ceramic shell is then removed from the cast part. Thereafter, the ceramic feed core and the RMC are removed, typically chemically, using a suitable removal technique. Removal of the RMC leaves the internal cooling circuit  96  within the component  60 . 
         [0056]      FIG. 4  illustrates an example core assembly  100  for forming the component  60 . The configuration of ceramic cores within the core assembly  100  allows access for removal of adhesive accumulated between the ceramic cores and the RMC before casting. The core assembly  100  includes a leading edge ceramic core  102 , an intermediate ceramic core  104 , and a trailing edge ceramic core  106 . The leading edge ceramic core  102 , the intermediate ceramic core  104 , and the trailing edge ceramic core  106  form the leading edge cooling passage  88 , the intermediate cooling passage  90 , and the trailing edge cooling passage  92 , respectively. In the illustrated example, an intermediate RMC  108  is attached to the intermediate ceramic core  104 . Although the illustrated example only shows one RMC  108  attached to the intermediate ceramic core  104 , additional RMCs could be attached to the leading edge ceramic core  102  and the trailing edge ceramic core  106 . 
         [0057]    The RMC  108  is used to form the internal cooling circuit  96  within the wall of the component  60 . The cooling circuit receives cooling fluid from the intermediate passage  90  once the component  60  is cast. In order for the internal cooling circuits  96  in the component  60  to receive cooling fluid from the intermediate passage  90 , the intermediate ceramic core  104  and the RMC  108  must be in contact with one another. The RMC  108  is secured to the intermediate ceramic core  104  to maintain contact during the casting process. In some embodiments, core assembly  100  can contain more than one intermediate ceramic core  104  and associated RMC  108 . 
         [0058]    During casting, the ceramic cores  102 ,  104 , and  106  form the cooling passages  88 ,  90 , and  92  within the airfoil  62  that travel in a generally spanwise direction (e.g., radially through a central region of the component  60 ). The leading edge ceramic core  102  includes an upstream surface  112 , a downstream surface  114 , a pressure side surface  116 , and a suction side surface  118 . The intermediate ceramic core  104  includes an upstream surface  120 , a downstream surface  122 , a pressure side surface  124 , and a suction side surface  126 . The trailing edge ceramic core  106  includes an upstream surface  130 , a downstream surface  132 , a pressure side surface  134 , and a suction side surface  136 . 
         [0059]    In the illustrated example, a recessed area  128  is formed along the pressure side surface  124  of the intermediate ceramic core  104  and extends in a spanwise and axial direction. In another example, the recessed area  128  could be formed on the suction side surface  126  or both the pressure side surface  124  and the suction side surface  126  of the intermediate ceramic core  104 . The recessed area  128  can extend the full span length of the intermediate ceramic cores  104  or only a portion of the full length of the intermediate ceramic core  104 . 
         [0060]    As shown in  FIGS. 4 and 5 , the intermediate RMC  108  includes a first end  140 , a second end  142 , a first side  144 , and a second side  146 . The first side  144  includes a contact surface  148  that is accepted within the recessed area  128 . In the illustrated example, the recessed area  128  extends from the downstream surface  122  on the intermediate ceramic core  104  to approximately 40-80% of the chord length of the intermediate ceramic core  104 . In another example, the contact surface  148  extends between 20-100% of the chord length of the intermediate ceramic core  104 . 
         [0061]    The RMC  108  is attached to the recessed area  128  of the intermediate core  104  with a ceramic adhesive or glue  110 . In one example, the ceramic adhesive  110  is applied to the RMC  108  prior to insertion into the recessed area  128  in the intermediate ceramic core  104 . The ceramic adhesive  110  secures the contact surface  148  within the recessed area  128  to form the cooling flow path between the intermediate cooling passage  90  and the internal cooling circuit  96  in the cast component  60 . 
         [0062]    Once cast, openings  150  in the RMC  108  form a plurality of pedestals or other features that direct cooling fluid through the internal cooling circuit  96 . The openings  150  can be circular, oblong, racetrack-shaped, teardrop-shaped or any other shape depending on the flow control needs of the cooling circuit. The RMC  108  can include one or more bends between the first and second ends  140  and  142  as shown in  FIGS. 4 and 5 . The bends in the RMC  108  allow the RMC  108  to be fed with cooling airflow from the intermediate cooling passage  90  and still provide a heat shielding effect on the intermediate passage  90  to reduce the temperature of the cooling airflow as it passes through the intermediate passage  90 . 
         [0063]    The ceramic adhesive  110  used to secure the RMC  108  to the intermediate ceramic core  104  can migrate and wick along the interface between intermediate ceramic core  104  and the RMC  108 . The overflow of the ceramic adhesive  110  can create undesired artifacts in the cast component, such as inclusions and fins, which can reduce the cooling effectiveness of the internal cooling circuits formed by the RMC  108  or impact the strength of the component  60 . 
         [0064]    To avoid the formation of these unwanted artifacts, excess ceramic adhesive  110  should be removed prior to forming the wax pattern. As shown in  FIG. 6 , a tool  152  is typically used to remove surplus ceramic adhesive  110 . The tool  152  can only remove surplus ceramic adhesive  110  along the regions of the RMC  108  that the tool  152  can access. Certain configurations of RMCs and ceramic cores prevent access to one side of the RMC where the ceramic adhesive  110  can wick, however. The embodiments described herein provide configurations that allow ceramic adhesive  110  removal from the interface of the RMC and the ceramic cores. 
         [0065]    As shown in  FIG. 6 , ceramic adhesive  110  has flowed out of the recessed area  128  and along the first side  140  of the RMC  108 . The ceramic adhesive  110  outside of the recessed area  128  can create the unwanted artifacts in the resulting cast component as described above.  FIG. 6  also illustrates the tool  152  that can be used to remove a surplus of the ceramic adhesive  110  that has flowed out of the recessed area  128  along the sides of the RMC  108  adjacent the intermediate ceramic core  104 . The tool  152  can be used to remove ceramic adhesive  110  on both the leading edge of the recessed area  128  and the first end  140  of the RMC  108  along the downstream surface  122  of the intermediate ceramic core  104 . Some prior art configurations would not allow the tool  152  to be used to remove the ceramic adhesive  110  from adjacent the RMC  108  due to spatial constraints. 
         [0066]    The tool  152  can be used to remove the ceramic adhesive  110  before or after the leading edge ceramic core  102 , the intermediate ceramic core  104 , and the trailing edge ceramic core  106  are assembled into the core assembly  100 . Because the ceramic cores  102 ,  104 , and  106  are separate elements, each ceramic core  102 ,  104 , and  106  and adjoining RMC can be assembled separately. That is, RMC  108  can be secured to the intermediate ceramic core  104  with ceramic adhesive  110  apart from the other ceramic cores and RMCs. The ceramic adhesive  110  can be removed by the tool  152  before the intermediate ceramic core  104  and the RMC  108  are assembled with the leading edge ceramic core  102  and the trailing edge ceramic core  106  to form the core assembly  100 . The ceramic adhesive  110  can be removed from both sides of the RMC  108  since no obstructions prevent access around the RMC  108 . Alternatively, ceramic adhesive  110  can be removed by the tool  152  after two or more of the ceramic cores of the core assembly  100  have been assembled. 
         [0067]      FIG. 7  illustrates another example leading edge ceramic core  202  and another example intermediate ceramic core  204 . Although  FIG. 7  does not include a trailing edge ceramic core, additional ceramic cores such as additional intermediate ceramic cores and trailing edge ceramic cores could be utilized. The intermediate ceramic core  204  includes an upstream surface  220 , a downstream surface  222 , a pressure side surface  224 , and a suction side surface  226 . In the illustrated example, a recessed area  228  is formed along the entire pressure side  224  of the intermediate core  204 . 
         [0068]    An intermediate RMC  208  is secured to the recessed area  228 . The RMC  208  includes a first end  230 , a second end  232 , and a first side  234 , and a second side  236 . A tab  238  extends from the first side  234  toward the upstream surface  220  of the intermediate ceramic core  204 . A contact surface  240  extends along the first side of the RMC  208  from the first end  230  to a distal end of the tab  238  for mating with the recessed area  228 . 
         [0069]    Excess ceramic adhesive  110  forms at the interfaces of the RMC  208  and the intermediate ceramic core  204 . The position of the excess ceramic adhesive  110  allows for easy access for removal by the tool  152 . 
         [0070]      FIG. 8  illustrates another example leading edge ceramic core  302  and another example intermediate ceramic core  304 . Although  FIG. 8  does not include a trailing edge ceramic core, additional ceramic cores such as additional intermediate ceramic cores and trailing edge ceramic cores could be utilized. The intermediate ceramic core  304  includes an upstream surface  320 , a downstream surface  322 , a pressure side surface  324 , and a suction side surface  326 . In the illustrated example, a recessed area  328  is formed along the entire pressure side  324  of the intermediate core  304 . The recessed area  328  includes a central slot  329  extending along a spanwise length of the intermediate ceramic core  304 . 
         [0071]    An intermediate RMC  308  includes a first end  330 , a second end  332 , and a first side  334 , and a second side  336 . A first tab  338  extends from the first side  334  toward the upstream surface  320  of the intermediate ceramic core  304  and a second tab  340  extends from the first side  334  toward into the slot  329 . The RMC  308  is inserted into the recessed area  328  by aligning the second tab  340  on the RMC  308  with the slot  329  in the recessed area  328 . A contact surface  342  extends from a distal end of the first tab  338  along the first side  334  around the second tab  340  to the first end  330  for mating with the recess  328 . 
         [0072]    Excess ceramic adhesive  110  forms at the interfaces of the RMC  308  and the intermediate ceramic core  304 . The position of the excess ceramic adhesive  110  allows for easy access for removal by the tool  152 . 
         [0073]      FIG. 9  illustrates another example leading edge ceramic core  402  and another example intermediate ceramic core  404 . Although  FIG. 9  does not include a trailing edge ceramic core, additional ceramic cores such as additional intermediate ceramic cores and trailing edge ceramic cores could be utilized. The intermediate ceramic core  404  includes an upstream surface  420 , a downstream surface  422 , a pressure side surface  424 , and a suction side surface  426 . In the illustrated example, a recessed area  428  is formed along a portion of the pressure side  424  of the intermediate core  404 . The recessed area  428  includes a slot  429  extending along a spanwise length of the intermediate ceramic core  404 . 
         [0074]    An intermediate RMC  408  includes a first end  430 , a second end  432 , a first side  434 , and a second side  436 . A first tab  438  extends from the first side  434  toward the slot  429 . In one example, the first tab  438  is perpendicular to the first side  434  and in another example, the first tab  438  is within  10  degrees of perpendicular. The RMC  408  is inserted into the recessed area  428  by aligning the first tab  438  on the RMC  408  with the slot  429  in the recessed area  428 . A contact surface  440  extends around the first tab  438  to the first end  432  of the RMC  408 . 
         [0075]    Excess ceramic adhesive  110  forms at the interfaces of the RMC  408  and the intermediate ceramic core  404 . The position of the excess ceramic adhesive  110  allows for easy access for removal by the tool  152 . 
         [0076]      FIG. 10  illustrates another example leading edge ceramic core  502  and another example intermediate ceramic core  504 . Although  FIG. 10  does not include a trailing edge ceramic core, additional ceramic cores such as additional intermediate ceramic cores and trailing edge ceramic cores could be utilized. The intermediate ceramic core  504  includes an upstream surface  520 , a downstream surface  522 , a pressure side surface  524 , and a suction side surface  526 . In the illustrated example, a recessed area  528  is formed along a portion of the pressure side  524  of the intermediate core  504 . The recessed area  528  includes an angled slot  529  extending along a length of the intermediate ceramic core  504 . 
         [0077]    An intermediate RMC  508  includes a first end  530 , a second end  532 , a first side  534 , and a second side  536 . A first tab  538  extends from the first side  434  toward the angled slot  529 . In one example, the first tab  538  extends at an angle of 45 degrees relative to the pressure side  524  and in another example, the first tab  538  extends within 35-55 degrees relative to the pressure side  524 . The RMC  508  is inserted into the recessed area  528  by aligning the first tab  538  on the RMC  508  with the angled slot  529  in the recessed area  528 . A contact surface  540  extends around the first tab  538  to the first end  532  of the RMC  508 . 
         [0078]    Excess ceramic adhesive  110  forms at the interfaces of the RMC  508  and the intermediate ceramic core  504 . The position of the excess ceramic adhesive  110  allows for easy access for removal by the tool  152 . 
         [0079]      FIG. 11  illustrates another example leading edge ceramic core  602  and another example intermediate ceramic core  604 . Although  FIG. 11  does not include a trailing edge ceramic core, additional ceramic cores such as additional intermediate ceramic cores and trailing edge ceramic cores could be utilized. The intermediate ceramic core  604  includes an upstream surface  620 , a downstream surface  622 , a pressure side surface  624 , and a suction side surface  626 , a first recessed area  628   a  on the pressure side surface  624  and a second recessed area  628   b  on the suction side surface  626 . 
         [0080]    A first RMC  608   a  includes a first end  630   a,  a second end  632   a,  a first side  634   a,  and a second side  636   a.  The first side  630   a  includes a contact surface  638   a  that is inserted into a recessed area  628   a  on the intermediate ceramic core  604 . In the illustrated example, the contact surface  638   a  extends from the downstream surface  622  on the intermediate core  604  to approximately 40-80% of the spanwise length of the intermediate core  604 . In another example, the contact surface  638   a  extends between 20-100% of the spanwise length of the intermediate core  604 . 
         [0081]    The first RMC  608   a  is attached to the first recessed area  628   a  of the intermediate core  604  with the ceramic adhesive  110 . The ceramic adhesive  110  secures the contact surface  638   a  within the recessed area  628   a  so that the first RMC  608   a  is secured to the recessed area  628   a  on the intermediate ceramic core  604 . 
         [0082]    A second RMC  608   b  includes a first end  630   b,  a second end  632   b,  a first side  634   b,  and a second side  636   b.  The first side  630   b  includes a contact surface  638   b  that is inserted into a recessed area  628   b  on the intermediate ceramic core  604 . In the illustrated example, the contact surface  638   b  extends from the downstream surface  622  on the intermediate core  604  to approximately 40-80% of the spanwise length of the intermediate core  604 . In another example, the contact surface  638   a  extends between 20-100% of the spanwise length of the intermediate core  604 . 
         [0083]    The second RMC  608   b  is attached to the second recessed area  628   b  of the intermediate core  604  with the ceramic adhesive  110 . The ceramic adhesive  110  secures the contact surface  638   b  within the recessed area  628   b  so that the second RMC  608   b  is secured to the recessed area  628   b  on the intermediate ceramic core  604 . 
         [0084]    Excess ceramic adhesive  110  forms at the interfaces forms at the interfaces of the first and second RMC  608   a,    608   b.  The position of the excess ceramic adhesive  110  allows for easy access for removal by the tool  152 . 
         [0085]      FIG. 12  illustrates another example leading edge ceramic core  702  and another example intermediate ceramic core  704 . Although  FIG. 12  does not include a trailing edge ceramic core, additional ceramic cores such as additional intermediate ceramic cores and trailing edge ceramic cores could be utilized. The intermediate ceramic core  704  includes an upstream surface  720 , a downstream surface  722 , a pressure side surface  724 , and a suction side surface  726 . A recessed area  728  extends at least partially along the pressure side surface  724 , the downstream surface  722 , and the suction side surface  726 . 
         [0086]    A RMC  708  includes a first end  730 , a second end  732 , a first side  734 , a second side  736 , and a pair of tabs  740 ,  742 . The first side  734  includes a contact surface  738  that is accepted within the recessed area  728  on the intermediate ceramic core  704 . The contact surface  738  extends between distal ends of the pair of tabs  740 ,  742  on the first side  734 . In the illustrated example, the pair of tabs  740 ,  742  extends from the downstream surface  722  on the intermediate core  704  to approximately 40-80% of the spanwise length of the intermediate core  704 . In another example, the contact surface  738  extends between 20-100% of the spanwise length of the intermediate core  704 . 
         [0087]    Excess ceramic adhesive  110  forms at the interface of the pair of tabs  740 ,  742  and the intermediate ceramic core  704 . The position of the excess ceramic adhesive  110  allows for easy access for removal by the tool  152 . 
         [0088]    Although the RMCs shown in  FIGS. 5-7  may be shown in a single ceramic core, the RMCs shown in  FIGS. 5-7  could be used with in the other ceramic cores in the core assembly  100 . 
         [0089]      FIG. 13  illustrates another example trailing edge ceramic core  806 . Although  FIG. 13  does not include a leading edge ceramic core and an intermediate ceramic core, additional ceramic cores could be utilized. The trailing ceramic core  806  includes an upstream surface  820 , a downstream surface  822 , a pressure side surface  824 , and a suction side surface  826 . In the illustrated example, a recessed area  828  is formed along the entire pressure side  824  of the intermediate core  806 . 
         [0090]    A trailing RMC  808  is secured to the recessed area  828 . The RMC  808  includes a first end  830 , a second end  832 , a first side  834 , and a second side  836 . A tab  338  extends from the first side  834  toward the upstream surface  820  of the intermediate ceramic core  804 . A contact surface  840  extends along the first side  834  of the RMC  808  from the first end  830  to a distal end of the tab  838  for mating with the recessed area  828 . 
         [0091]    Excess ceramic adhesive  110  forms at the interfaces of the RMC  808  and the intermediate ceramic core  804 . The position of the excess ceramic adhesive  110  allows for easy access for removal by the tool  152 . 
         [0092]      FIG. 14  illustrates another example RMC  908  adjacent a leading edge ceramic core  902  and an intermediate ceramic core  904 . The RMC  908  includes a first end  930 , a second end  932 , a first side  934 , and a second side  936 . The leading edge ceramic core  902  and the intermediate ceramic core  904  are held together by a formation  935  that will form a first impingement hole fluidly connecting the leading edge ceramic core  902  and the intermediate ceramic core  904  in the cast component. 
         [0093]    The second side  936  is located adjacent the leading edge ceramic core  902  and a pressure side  924  and a suction side  926  of the intermediate ceramic core  904 . When the component  60  is cast, the RMC  908  will form a second impingement cooling passage  938  and a third impingement cooling passage  940  as shown in  FIG. 15 . The addition of the cooling second and third impingement cooling passages  938  and  940  will improve cooling of the component  60 . 
         [0094]    Excess ceramic adhesive  110  forms at the interfaces of the RMC  908  and the intermediate ceramic core  904 . The position of the excess ceramic adhesive  110  allows for easy access for removal by the tool  152  along the trail edge, but not along the first side  934  of the RMC  908 . 
         [0095]    Although the different non-limiting embodiments are illustrated as having specific components, the embodiments of this disclosure are not limited to those particular combinations. It is possible to use some of the components or features from any of the non-limiting embodiments in combination with features or components from any of the other non-limiting embodiments. 
         [0096]    It should be understood that like reference numerals identify corresponding or similar elements throughout the several drawings. It should also be understood that although a particular component arrangement is disclosed and illustrated in these exemplary embodiments, other arrangements could also benefit from the teachings of this disclosure. 
         [0097]    The foregoing description shall be interpreted as illustrative and not in any limiting sense. A worker of ordinary skill in the art would understand that certain modifications could come within the scope of this disclosure. For these reasons, the following claim should be studied to determine the true scope and content of this disclosure.