Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: An apparatus and method for forming a film hole in an outer wall of an airfoil. The film hole includes a blind opening adjacent the interior of the airfoil and a hole adjacent the exterior of the airfoil. The blind opening fluidly couples to the hole to form the film hole for providing a volume of fluid as a surface cooling film along the exterior of the outer wall.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: An apparatus and method for cooling a blade tip for a turbine engine can include an blade, such as a cooled turbine blade, having a tip rail extending beyond a tip wall enclosing an interior for the blade at the tip. A plurality of film-holes can be provided in the tip rail. A flow of cooling fluid can be provided through the film-holes from the interior of the blade to cool the tip of the blade.

Abstract: An apparatus and method for forming a film hole in an outer wall of an airfoil. The film hole includes a blind opening adjacent the interior of the airfoil and a hole adjacent the exterior of the airfoil. The blind opening fluidly couples to the hole to form the film hole for providing a volume of fluid as a surface cooling film along the exterior of the outer wall.

Abstract: An apparatus and method for cooling a component for a turbine engine which generates a hot gas flow and provides a cooling fluid flow, the component comprising a body having an outer surface, at least a portion of which is exposed to the hot gas flow to define a hot surface, a cooling cavity located within the body and fluidly coupled to the cooling fluid flow and a pin located within the cooling cavity and defining a cooling hole.

Abstract: An apparatus and method an engine component for a turbine engine comprising an outer wall bounding an interior and defining a pressure side and an opposing suction side, with both sides extending between a leading edge and a trailing edge to define a chord-wise direction, and extending between a root and a tip to define a span-wise direction, at least one cooling passage located within the interior, at least one cooling hole having an inlet fluidly coupled to the cooling passage and an outlet located along the outer wall.

Abstract: A component for a gas turbine engine. The component includes a body. The body has an exterior surface abutting a flowpath for the flow of a hot combustion gas through the gas turbine engine. Further, the body defines a cooling passageway within the body to supply cool air to the component. The component includes a leading face and a trailing face defining a trench therebetween on the exterior surface. The body defines a plurality of cooling holes extending between the cooling passageway and a plurality of outlets defined in the trench such that the trench is fluidly coupled to the cooling passageway. Additionally, the leading face and trailing face are each tangent to at least one of the plurality of outlets. The trench directs the cool air along a contour of the component.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud. The disclosure also relates to the forming of a ceramic coating on at least a portion of the shell of the core-shell casting mold.

Abstract: An apparatus and method relating to a cooling hole of a component of a turbine engine. The cooling hole can extend from an inlet to an outlet to define a passage. The cooling hole can include a laid back section where a coating can be applied. The method can include forming the cooling hole in the component and applying the coating to the component to maintain a specific geometry.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud. The disclosure also relates to the forming of a ceramic coating on at least a portion of the shell of the core-shell casting mold.

Abstract: A method of forming a cast component and a method of forming a casting mold is generally provided. The method is performed by plugging or covering an opening in a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process. At least a portion of the ceramic core-shell mold and the plug or cover is coated with a second ceramic material.

Abstract: A method of forming a cast component and a method of forming a casting mold is generally provided. The method is performed by plugging or covering an opening in a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process. At least a portion of the ceramic core-shell mold and the plug or cover is coated with a second ceramic material.

Abstract: An apparatus and method an engine component for a turbine engine comprising an outer wall bounding an interior and defining a pressure side and an opposing suction side, with both sides extending between a leading edge and a trailing edge to define a chord-wise direction, and extending between a root and a tip to define a span-wise direction, at least one cooling passage located within the interior, at least one cooling hole having an inlet fluidly coupled to the cooling passage and an outlet located along the outer wall.

Abstract: An apparatus and method an engine component for a turbine engine comprising an outer wall bounding an interior and defining a pressure side and an opposing suction side, with both sides extending between a leading edge and a trailing edge to define a chord-wise direction, and extending between a root and a tip to define a span-wise direction, at least one cooling passage located within the interior, at least one cooling hole having an inlet fluidly coupled to the cooling passage and an outlet located along the outer wall.

Abstract: The present disclosure generally relates to methods and apparatuses for forming cast parts having cast in features aligned with a casting core. The part is cast around a casting core within a casting shell. The casting core has a first feature that creates a corresponding second feature of the cast part. The casting core includes a third alignment feature that creates a corresponding fourth feature of the cast part spaced apart from the second feature of the cast part. A machining tool is aligned with the second feature of the cast part based on the fourth feature of the cast part. The machining tools machines the cast part to create the at least one passageway aligned with the second feature.

Abstract: An apparatus and method for an engine component for a turbine engine comprising an outer wall bounding an interior and defining a pressure side and an opposing suction side, with both sides extending between a leading edge and a trailing edge to define a chord-wise direction, and extending between a root and a tip to define a span-wise direction, at least one cooling passage located within the interior, at least one cooling hole having an inlet fluidly coupled to the cooling passage, an outlet located proximate the leading edge, with a connecting passage fluidly coupling the inlet to the outlet.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide tongue or groove structures corresponding, respectively, to groove or tongue structures in the surface of the turbine blade or stator vane, including in locations that are otherwise inaccessible. The groove and tongue structures also provide a pathway to restrict cooling flow between turbine blades to the flowpath.

Abstract: An apparatus and method an engine component for a turbine engine comprising an outer wall bounding an interior and defining a pressure side and an opposing suction side, with both sides extending between a leading edge and a trailing edge to define a chord-wise direction, and extending between a root and a tip to define a span-wise direction, at least one cooling passage located within the interior, a set of cooling holes having an inlet fluidly coupled to the cooling passage, an outlet located on one of the pressure side or suction side, with a connecting passage fluidly coupling the inlet to the outlet.

Abstract: A shroud for a turbine engine includes a body having a first surface with an inlet fluidly coupled to a cooling fluid flow, and a second surface facing a heated fluid flow. A cavity within the body can be fluidly coupled to the inlet and include an impingement zone thermally coupled to the second surface.