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; energizing a primary inductive coil within the chamber to heat the mold via radiation from a susceptor, wherein the resultant electromagnetic field partially leaks through the susceptor coupled to the chamber between the primary inductive coil and the mold; determining a magnetic flux profile of the electromagnetic field; sensing a magnetic flux leakage past the susceptor within the chamber; generating a control field from a secondary compensation coil coupled to the chamber, wherein the control field controls the magnetic flux experienced by the cast part; and casting the material within the mold under the controlled degree of flux leakage.

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 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 chamfered stator vane rail is provided. The chamfered stator vane rail may comprise a forward rail and an aft rail axially opposite the forward rail. The aft rail may comprise a leading edge and a trailing edge located axially opposite and aft of the leading edge. The aft rail may comprise a chamfered edge on a radially outer surface. The chamfered edge may be oriented at an angle relative to an axis.

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: A core for use in casting an internal cooling circuit within a gas turbine engine component includes an additively manufactured skeleton core portion manufactured of a refractory metal, a surround core portion that at least partially encapsulates the additively manufactured skeleton core portion, the surround core portion manufactured of a ceramic material, a surround core portion that at least partially encapsulates the additively manufactured skeleton core portion, the surround core portion manufactured of a ceramic material and a cooling hole shape that extends from the additively manufactured skeleton core portion through the surround core portion, the cooling hole shape operable to form a cooling hole.

Abstract: Combustor panels for use in gas turbine engines having a panel body having a first side and a second side, and a plurality of cooling pins extending from the first side, the plurality of cooling pins arranged in a pin array pattern, wherein at least some of the cooling pins extend a first height from the first side of the panel body, each cooling pin having a pin width, and is separated from adjacent cooling pins of the pin array by a pin array separation distance. The pin array separation distance is equal to or greater than the pin width.

Abstract: A method for evaluating a turbine component includes inducing a thermal response of the component at an initial time, capturing a two-dimensional infrared image of the thermal response of the component with a thermal imaging device, wherein the two-dimensional infrared image comprises a plurality of infrared image pixels, generating a two-dimension to three-dimension mapping template to correlate two-dimensional infrared image data with three-dimensional locations on the component, mapping at least a subset of the plurality of infrared image pixels of the two-dimensional infrared image to three-dimensional coordinates using the mapping template, and generating a three-dimensional infrared image and infrared data of the component from the mapped infrared image pixels to three-dimensional coordinates, wherein the three-dimensional infrared image and infrared data is used to qualify the component for use.

Abstract: A method of manufacturing a core for casting a component can include manufacturing a core for at least partially forming an internal passage architecture of a component with a material including radiopaque particles. A method can include removing a material including radio opaque particles from an internal passage architecture of a component; and inspecting the component via radiographic imaging at gamma/X-ray wavelengths to detect residual material. A core for use in casting an internal passage architecture of a component can include a material with radiopaque particles dispersed therein.

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 gas turbine engine blade includes a platform that has an inner side and an outer side, a root that extends outwardly from the inner side, and an airfoil that extends outwardly from a base at the outer side to a tip end. The airfoil includes a leading edge and a trailing edge and a first side wall and a second side wall. The first side wall and the second side wall join the leading edge and the trailing edge and at least partially define one or more cavities in the airfoil. The airfoil has a span from the base to the tip end, with the base being at 0% of the span and the tip end being at 100% of the span. The first side wall includes an axial row of cooling holes at 90% or greater of the span.

Abstract: A chamfered stator vane rail is provided. The chamfered stator vane rail may comprise a forward rail and an aft rail axially opposite the forward rail. The aft rail may comprise a leading edge and a trailing edge located axially opposite and aft of the leading edge. The aft rail may comprise a chamfered edge on a radially outer surface. The chamfered edge may be oriented at an angle relative to an axis.

Abstract: A method for evaluating a turbine component includes inducing a thermal response of the component at an initial time, capturing a two-dimensional infrared image of the thermal response of the component with a thermal imaging device, wherein the two-dimensional infrared image comprises a plurality of infrared image pixels, generating a two-dimension to three-dimension mapping template to correlate two-dimensional infrared image data with three-dimensional locations on the component, mapping at least a subset of the plurality of infrared image pixels of the two-dimensional infrared image to three-dimensional coordinates using the mapping template, and generating a three-dimensional infrared image and infrared data of the component from the mapped infrared image pixels to three-dimensional coordinates, wherein the three-dimensional infrared image and infrared data is used to qualify the component for use.

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 gas turbine engine component has a component body configured to be positioned within a flow path of a gas turbine engine, wherein the component body includes at least one internal cavity. At least one inlet opening is formed in an outer surface of the component body to direct flow into the at least one internal cavity. At least one outlet from the internal cavity, wherein the at least one outlet is located at a lower pressure area in the internal cavity than the at least one inlet opening such that flow is drawn into the internal cavity from the at least one inlet opening and expelled out the at least one outlet. A gas turbine engine and a method of enhancing laminar flow for a gas turbine engine component are also disclosed.

Abstract: A hollow metal article can be fabricated by casting a molten metal alloy around a core, solidifying the molten metal alloy to form a metal article, and chemically removing the core from the metal article to form a hollow cavity in the metal article. The core includes a ceramic core body and an x-ray radiopaque coating disposed on the ceramic core body. A method for testing the hollow metal article includes submitting the hollow metal article to x-ray imaging and determining based upon the x-ray imaging whether any of the x-ray radiopaque coating of the core remains in the hollow metal article.

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 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 core for use in casting an internal cooling circuit within a gas turbine engine component includes an additively manufactured skeleton core portion manufactured of a refractory metal, a surround core portion that at least partially encapsulates the additively manufactured skeleton core portion, the surround core portion manufactured of a ceramic material, a surround core portion that at least partially encapsulates the additively manufactured skeleton core portion, the surround core portion manufactured of a ceramic material and a cooling hole shape that extends from the additively manufactured skeleton core portion through the surround core portion, the cooling hole shape operable to form a cooling hole.

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.