Abstract: A manufacturing method includes forming one or more grooves in a component that comprises a substrate with an outer surface. The substrate has at least one interior space. Each groove extends at least partially along the substrate and has a base and a top. The manufacturing method further includes applying a structural coating on at least a portion of the substrate and processing at least a portion of the surface of the structural coating so as to plastically deform the structural coating at least in the vicinity of the top of a respective groove, such that a gap across the top of the groove is reduced. A component is also disclosed and includes a structural coating disposed on at least a portion of a substrate, where the surface of the structural coating is faceted in the vicinity of the respective groove.

Abstract: A method of machining a component is provided. The component includes a substrate having an outer surface and an inner surface, where the inner surface defines at least one interior space. A core is disposed within each interior space. The method includes forming at least one hole in the substrate while the core is disposed within the respective interior space. Each hole extends through the substrate to provide fluid communication with the respective interior space. The method further includes removing the core from the respective interior space. The core may be a casting core or a subsequently formed core.

Abstract: A method of manufacture is provided. The manufacturing method includes using a laser deposition process to apply a laser deposited material on an outer surface of a substrate to form one or more grooves on the outer surface of a substrate. Each groove has a base and an opening and extends at least partially along the outer surface of the substrate, where the substrate has an inner surface that defines at least one hollow, interior space. The manufacturing method further includes disposing an additional material over the laser deposited material, to define one or more channels for cooling the component. The additional material may include additional laser deposited material layers or a coating. Other manufacturing methods and a component are also provided.

Abstract: A component includes a substrate having an outer surface, an inner surface and a tip. The inner surface defines at least one hollow, interior space. The outer surface defines one or more grooves, where each groove extends at least partially along the outer surface of the substrate and has a base. The component further includes a coating disposed over at least a portion of the outer surface of the substrate. The coating includes at least a structural coating that extends over the groove(s), such that the groove(s) and the structural coating together define one or more channels for cooling the component. The tip comprises a tip cap enclosing the hollow, interior space(s), and a tip rim disposed at a radially outer end of the substrate. The tip rim at least partially defines at least one discharge channel in fluid communication with at least one cooling channel.

Abstract: A method of machining a component is provided. The component includes a substrate having an outer surface and an inner surface, where the inner surface defines at least one interior space. A core is disposed within each interior space. The method includes forming at least one hole in the substrate while the core is disposed within the respective interior space. Each hole extends through the substrate to provide fluid communication with the respective interior space. The method further includes removing the core from the respective interior space. The core may be a casting core or a subsequently formed core.

Abstract: A manufacturing method includes forming one or more grooves in a component that comprises a substrate with an outer surface. The substrate has at least one interior space. Each groove extends at least partially along the substrate and has a base and a top. The manufacturing method further includes applying a structural coating on at least a portion of the substrate and processing at least a portion of the surface of the structural coating so as to plastically deform the structural coating at least in the vicinity of the top of a respective groove, such that a gap across the top of the groove is reduced. A component is also disclosed and includes a structural coating disposed on at least a portion of a substrate, where the surface of the structural coating is faceted in the vicinity of the respective groove.

Abstract: A method of fabricating a component is provided. The component includes a substrate that has at least one interior space. The method includes forming one or more grooves in the component. Each groove extends at least partially along an outer surface of the substrate and narrows at an opening thereof, such that each groove is re-entrant shaped. A cross-sectional area A of each groove is in a range of about 2 to about 3 times an area R=W*D, where W is the width of the opening and D is the depth of the re-entrant-shaped groove. Components with grooves formed in the substrate and components with grooves formed at least partially in a structural coating are also provided.

Abstract: A method of forming cooling channels in a component is provided. The component has a substrate having outer and inner surfaces. The inner surface defines at least one interior space, and a core is disposed within each interior space. The method includes forming at least one access hole in the substrate, while the core is disposed within the respective interior space, removing the core from the respective interior space, and forming at least one groove in the outer substrate surface (before or after the core is removed). Each access hole connects the groove in fluid communication with the respective interior space. The method further includes disposing a coating over at least a portion of the outer substrate surface, where the coating includes at least a structural coating that extends over the groove(s), such that the groove(s) and the structural coating together define one or more channels configured to convey a coolant from the respective interior space(s) for cooling the component.

Abstract: A component includes a substrate that has outer and inner surfaces. The inner surface defines at least one hollow, interior space. The outer surface defines pressure and suction sidewalls that are joined together at leading and trailing edges of the component and together form an airfoil portion of the component. The outer substrate surface further defines at least one platform and at least one fillet that extends between and integrally connects the airfoil to the respective platform. The outer surface defines one or more grooves that extend at least partially along a respective fillet. Each groove is in fluid communication with a respective hollow, interior space. The component further includes a coating disposed over at least a portion of the outer substrate surface and including at least a structural coating that extends over the groove(s). The groove(s) and the structural coating together define channel(s) for cooling the respective fillet.

Abstract: A method of machining a component is provided. The component includes a substrate having an outer surface and an inner surface, where the inner surface defines at least one interior space. A core is disposed within each interior space. The method includes forming at least one hole in the substrate while the core is disposed within the respective interior space. Each hole extends through the substrate to provide fluid communication with the respective interior space. The method further includes removing the core from the respective interior space. The core may be a casting core or a subsequently formed core.

Abstract: A component is provided and includes a substrate comprising an outer and an inner surface, where the inner surface defines at least one hollow, interior space. The component defines one or more grooves, where each groove extends at least partially along the outer surface of the substrate and has a base and a top. The base is wider than the top, such that each groove comprises a re-entrant shaped groove. One or more access holes are formed through the base of a respective groove, to connect the groove in fluid communication with the respective hollow interior space. Each access hole has an exit diameter D that exceeds the opening width d of the top of the respective groove. The diameter D is an effective diameter based on the area enclosed. The component further includes at least one coating disposed over at least a portion of the surface of the substrate, wherein the groove(s) and the coating together define one or more re-entrant shaped channels for cooling the component.

Abstract: A manufacturing method is provided. The manufacturing method includes forming one or more grooves in a component comprising a substrate. Each groove extends at least partially along the substrate and has a base, a top and at least one discharge end. The manufacturing method further includes forming a crater, such that the crater is in fluid connection with the respective discharge end for each groove, and disposing a coating over at least a portion of an outer surface of the substrate. The groove(s) and the coating together define one or more channels for cooling the component. The coating does not completely bridge each of the one or more craters, such that each crater defines a film exit. A component with cratered film exits is also provided.

Abstract: A component is provided and includes a substrate comprising an outer and an inner surface, where the inner surface defines at least one hollow, interior space. The component defines one or more grooves, where each groove extends at least partially along the outer surface of the substrate and has a base and a top. The base is wider than the top, such that each groove comprises a re-entrant shaped groove. One or more access holes are formed through the base of a respective groove, to connect the groove in fluid communication with the respective hollow interior space. Each access hole has an exit diameter D that exceeds the opening width d of the top of the respective groove. The diameter D is an effective diameter based on the area enclosed. The component further includes at least one coating disposed over at least a portion of the surface of the substrate, wherein the groove(s) and the coating together define one or more re-entrant shaped channels for cooling the component.

Abstract: An engine component with particulate mitigation features is provided. The engine component comprises an internal engine component surface having a cooling flow path on one side thereof and a second component adjacent to the first component. The second component, for example an insert, may have a plurality of openings forming an array wherein the openings extend through the second component at a non-orthogonal angle to the surface of the second component.

Abstract: A manufacturing method includes providing a substrate with an outer surface and at least one interior space, applying a coating on a portion of the substrate and forming one or more grooves in the coating, wherein each groove extends at least partially along the coating. The method further includes processing at least a portion of the surface of the coating to plastically deform the coating in the vicinity of the top of a respective groove. An additional coating is applied over at least a portion of the surface of the coating. A component is disclosed and includes a substrate, a coating disposed on at least a portion of the substrate, and defining one or more grooves therein, and an additional coating disposed over at least a portion of the coating. The substrate, the coating and the additional coating together define one or more channels for cooling the component.

Abstract: A method for repairing a component is provided, where the component has a substrate comprising an outer surface and an inner surface and defining one or more grooves. Each groove extends at least partially along the outer surface of the substrate. The component further includes a structural coating, a bond coating, and a thermal barrier coating. The groove(s) and the structural coating define one or more channels for cooling the component. The repair method includes removing the thermal barrier and bond coatings, removing at least a portion of the structural coating in a vicinity of a damaged portion of the component, performing a repair operation on the damaged portion of the component, applying a structural coating at least in a vicinity of the repaired portion of the component, and applying a bond coating and a thermal barrier coating. Additional repair methods are also provided.

Abstract: A manufacturing method includes providing a substrate having one or more grooves formed therein. One or more coatings having one or more grooves formed therein are disposed on the substrate and in fluid communication with the one or more grooves in the substrate. A cover coating is disposed on a portion of an outermost surface of the one or more coatings, having one or more cooling outlets formed therein and in fluid communication with the one or more grooves in the one or more coatings. The substrate, the one or more coatings and the cover coating define therein a cooling network for cooling a component. A component having a cooling network defined therein a substrate, one or more coatings disposed on at least a portion of the substrate, and a cover coating disposed over at least a portion of an outermost coating of the one or more coatings.

Abstract: A method to modify the shape of a channel in a metallic substrate is described. The method includes the step of applying at least one metallic coating on selected portions of an interior surface of the channel, so as to alter the heat transfer characteristics of the channel during passage of a coolant fluid therethrough. Related articles that contain the modified channels are also described, such as gas turbine engine components.

Abstract: A method for the formation of channels on a metallic substrate is described. The method includes the steps of applying at least one layer of a metallic coating material onto a surface of the substrate by a cold spray technique, so as to define boundary walls for the channels, and to build the boundary walls to a desired height. Additional coating material is then applied on one or more surfaces of the boundary walls by the cold spray technique, so as to modify the shape of the channels. The substrate can be any type of high-temperature component or hot gas path component. In some instances, the substrate is a gas turbine engine wall.

Abstract: An airfoil and method of cooling a airfoil including a leading edge, a trailing edge, a suction side, a pressure side and at least one internal cooling channel configured to convey a cooling fluid, is provided. A plurality of trailing edge bleed slots are in fluid communication with the at least one internal cooling channel, wherein a downstream edge of the pressure side of the airfoil lies upstream of a downstream edge of the suction side to expose the plurality of trailing edge bleed slots proximate to the trailing edge of the airfoil. The at least one internal cooling channel is configured to supply the cooling fluid from a source of cooling fluid towards the plurality of trailing edge bleed slots. A plurality of obstruction features are disposed within the at least one internal cooling channel and at a downstream edge of the remaining pressure side.