Abstract: A method of forming a component having an internal passage defined therein is provided. The method includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed at least partially by an additive manufacturing process, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core is positioned to define the internal passage within the component.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure that includes an interior portion shaped to define at least one interior passage feature of the internal passage. The jacketed core also includes an inner core disposed within the hollow structure and complementarily shaped by the interior portion of the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold to form the component, such that the inner core defines the internal passage including the at least one interior passage feature defined therein.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from at least a first material and a first catalyst, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

Abstract: A drilling tool for use in machining a conductive work piece is provided. The tool includes a body portion, a forward electrode coupled to the body portion, and at least one side electrode coupled to the body portion. When electric current is supplied to the forward electrode and the at least one side electrode, material adjacent to the forward electrode and the at least one side electrode is removed from the conductive work piece. Further, the forward electrode and the at least one side electrode are selectively operable to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from at least a first material and a first catalyst, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core defines the internal passage within the component.

Abstract: A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure that includes an interior portion shaped to define at least one interior passage feature of the internal passage. The jacketed core also includes an inner core disposed within the hollow structure and complementarily shaped by the interior portion of the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold to form the component, such that the inner core defines the internal passage including the at least one interior passage feature defined therein.

Abstract: A method of forming a component having an internal passage defined therein is provided. The method includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed at least partially by an additive manufacturing process, and an inner core disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, and cooling the component material in the cavity to form the component. The inner core is positioned to define the internal passage within the component.

Abstract: A drilling tool for use in machining a conductive work piece is provided. The tool includes a body portion, a forward electrode coupled to the body portion, and at least one side electrode coupled to the body portion. When electric current is supplied to the forward electrode and the at least one side electrode, material adjacent to the forward electrode and the at least one side electrode is removed from the conductive work piece. Further, the forward electrode and the at least one side electrode are selectively operable to form a bore hole having a variable geometry that extends through the conductive work piece when the material is removed therefrom.