Abstract: A gas turbine engine component has a component body configured to be positioned within a flow path of a gas turbine engine having an external pressure, and wherein the component body includes at least one internal cavity having an internal pressure. At least one inlet opening is formed in an outer surface of the component body to direct hot exhaust gas flow into the at least one internal cavity, and there is at least one outlet from the internal cavity. The internal pressure is less than an inlet external pressure at the inlet opening and the internal pressure is greater than an outlet external pressure at the outlet opening to controllably ingest hot exhaust gas via the inlet opening and expel the hot exhaust gas via the outlet opening to maintain a laminar boundary layer along the outer surface of the component body.

Abstract: A method of forming an airfoil includes casting the airfoil with an internal cooling circuit and an exterior surface with a positive feature. The exterior surface of the airfoil is scanned with a first probe. A size and a location of the positive feature are identified based on the scan of the exterior surface. A transformation matrix is created with a controller such that the transformation matrix includes toolpath transformation instructions. A transformed set of machine toolpath instructions is created by applying the transformation matrix using the controller to a first set of machine toolpath instructions to align the first set of machine toolpath instructions relative to the positive feature. A contour is then machined into the exterior surface of the airfoil based on the transformed set of machine toolpath instructions.

Abstract: A heat shield panel for use in a gas turbine engine combustor is disclosed. The heat shield panel includes a hot side, a cold side and at least one attachment mechanism having a stud and a central axis extending through the stud and a plurality of standoff pins positioned circumferentially around the stud, the standoff pins having a radial extent, a circumferential extent that is greater than the radial extent, a radially outer surface having a radially convex shape and a radially inner surface having a radially concave shape.

Abstract: An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber.

Abstract: A component for a gas turbine engine includes a body portion that extends between a leading edge and a trailing edge of the component. The trailing edge includes a flared region and a non-flared region. At least one discharge slot is disposed at least partially within the flared region of the component.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold.

Abstract: A blade outer air seal includes a seal body that has a channel on a radially inner side that defines a first height portion outside of the channel and a second height portion within the channel. A first cavity is in the first height portion and a second cavity is in the second height portion. An abradable coating is over the radially inner side and fills the first and second cavities.

Abstract: A method of removing features from a cast workpiece includes generating a nominal toolpath for machining the cast workpiece. The cast workpiece is mounted onto a platform of a computer numeric control machine. The cast workpiece is inspected with a probe to generate probe data. Features to be removed are identified based upon the probe data generated during the inspection. Any expected features of the cast workpiece that are missing from the cast workpiece are identified. A transformation matrix is applied to the nominal toolpath with a controller of the computer numeric control machine, wherein the transformation matrix is based upon the probe data. Alignment of the cast workpiece is adjusted relative to the computer numeric control machine based on the transformation matrix with the computer numeric control machine. Features are removed from the cast workpiece that were identified during inspection.

Abstract: A process for directional solidification of a cast part comprises energizing a primary inductive coil coupled to a chamber having a mold containing a material; generating an electromagnetic field with the primary inductive coil within the chamber, wherein said electromagnetic field is partially attenuated by a susceptor coupled to said chamber between said primary inductive coil and said mold; determining a magnetic flux profile of the electromagnetic field after it passes through the susceptor; sensing a component of the magnetic flux in the interior of the susceptor proximate the mold; positioning a mobile secondary compensation coil within the chamber; generating a control field from a secondary compensation coil, wherein said control field controls said magnetic flux; and casting the material within the mold.

Abstract: A component according to an exemplary aspect of the present disclosure includes, among other things, a body, a wall extending inside of the body and a plurality of vortex promoting features arranged in a helical pattern along the wall.

Abstract: A system for automated adaptive manufacturing of airfoil castings is disclosed. The system may receive a three dimensional scan of a work piece. The system may compare the three dimensional scan to a digital model of the work piece. The system may identify an area of dimensional abnormality on the work piece based on the comparison. The system may alter the area of dimensional abnormality on the work piece.

Abstract: A turbine airfoil includes an airfoil outer wall that defines leading and trailing ends and first and second sides that join the leading and trailing ends. At least one cooling passage is embedded in the airfoil outer wall and has a radially-elongated entrance manifold, a radially-elongated diffuser orifice that opens to an exterior surface of the airfoil outer wall, and a bank of sub-passages fluidly connecting the radially-elongated entrance manifold with the radially-elongated diffuser orifice. The radially-elongated diffuser orifice is sloped relative to the radially-elongated entrance manifold.

Abstract: An airfoil of a gas turbine engine is provided including a leading edge extending in a radial direction, a tip extending in an axial direction from the leading edge, a first rib extending radially within the airfoil, the leading edge and the first rib defining a leading edge cavity within the airfoil, a second rib, the second rib and the first rib defining a serpentine cavity therein, a third rib extending axially within the tip, a flag tip cavity defined by the third rib, the leading edge, and the tip, the leading edge cavity fluidly connected to the flag tip cavity, and a bypass aperture formed between the first rib and the third rib, the bypass aperture configured to fluidly connect the serpentine cavity with the flag tip cavity.

Abstract: A method of forming a component includes the steps of placing a core into a mold and pouring a component material around the core. The component material is allowed to solidify. The core is then removed from within the material, leaving a component having at least a first and a second cavity formed by the core. A first filler material is moved into the first cavity, and a second filler material is moved into the second cavity. The component is inspected for the presence of an apparent residual core within the first cavity and the second cavity. The location is identified of the apparent residual core from the core based upon an identification of whether the location of the apparent residual core is in the first or second filler materials. A method of inspecting a component formed by investment casting is also disclosed.

Abstract: A heat shield panel for use in a gas turbine engine combustor is disclosed. The heat shield panel includes a hot side, a cold side and at least one attachment mechanism having a stud and a central axis extending through the stud and a plurality of standoff pins positioned circumferentially around the stud, the standoff pins having a radial extent, a circumferential extent that is greater than the radial extent, a radially outer surface having a radially convex shape and a radially inner surface having a radially concave shape.

Abstract: A refractory metal core laminate assembly, comprising: a first refractory metal core layer having exterior surfaces and a first side and a second side opposite the first side; a second refractory metal core layer having exterior surfaces and a first side and a second side opposite the first side, the second refractory metal core layer being arranged above the first refractory metal core layer with the second refractory metal core layer first side facing the first refractory metal core layer second side; a layer of a powder bed material between the first refractory metal core layer second side and the second refractory metal core layer first side; and a coating of the powder bed material coupled to the first refractory metal core layer exterior surfaces and the second refractory metal core layer exterior surfaces.

Abstract: An airfoil of a gas turbine engine includes an airfoil body having a leading edge and a trailing edge extending in a radial direction, a trailing edge cavity formed within the airfoil and proximate to the trailing edge of the airfoil, the trailing edge cavity extending from the trailing edge in a forward direction toward the leading edge, at least one set of blocking pedestals located within the trailing edge cavity, a set of circular pedestals located aftward from the at least one blocking set of pedestals, and a set of spear pedestals located aftward from the set of circular pedestals and closest to the trailing edge of the airfoil body.

Abstract: An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a susceptor surrounding the chamber between the primary inductive coil and the mold; and a shield material contained in a reservoir coupled to or proximate the mold between the susceptor and the mold; the shield material configured to attenuate a portion of an electromagnetic flux generated by the primary induction coil that is not attenuated by the susceptor.

Abstract: A core for use in casting an internal cooling circuit within a gas turbine engine component includes a base core portion and an additive core portion additively manufactured to the base core portion. A method of manufacturing a core for use in casting an internal cooling circuit within a gas turbine engine component including additively manufacturing an additive core portion to a base core portion.

Abstract: An induction furnace assembly comprising a chamber having a mold; a primary inductive coil coupled to the chamber; a layered susceptor comprising at least two layers of magnetic field attenuating material surrounding the chamber between the primary inductive coil and the mold to nullify the electromagnetic field in the hot zone of the furnace chamber.