Abstract: A method of manufacturing a tooling assembly and the tooling assembly (10) for ceramic cores. The tooling assembly includes a backing plate (12) comprising a top surface (20), side surfaces (18), and a bottom surface (16) and a plurality of lithographically derived inserts (14) each having a bottom surface (24), side surfaces (26), and a positive top surface (28) and pieced together on the top surface (20) of the backing plate (12). The method includes providing the backing plate (12) and plurality of lithographically derived inserts (14). A non-conformal positive surface is generated from the plurality of lithographically derived inserts (14). A negative flexible mold is created from the non-conformal positive surface. The negative flexible mold is then prepared for casting for an advanced ceramic core.

Abstract: A method of manufacturing protruding cast in features (10). At least one core insert (12) is manufactured using small particle sizes. A bulk core body is manufactured using large particle sizes. The at least one core insert (12) and bulk core body are fully fired separately. The at least one core insert (12) is bonded with the bulk core body.

Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, and/or composition of matter configured for and/or resulting from, and/or a method for, activities that can comprise and/or relate to, investment casting a product in a mold, the product comprising at least one wall, the mold comprising a core, an inner primary shell, and an outer secondary shell.

Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, and/or composition of matter configured for and/or resulting from, and/or a method for, activities that can comprise and/or relate to, investment casting a product in a mold, the product comprising at least one wall, the mold comprising a core, an inner primary shell, and an outer secondary shell.

Abstract: A cooling channel (36, 36B) cools an exterior surface (40 or 42) or two opposed exterior surfaces (40 and 42). The channel has a near-wall inner surface (48, 50) with a width (W1). Interior side surfaces (52, 54) may converge to a reduced channel width (W2). The near-wall inner surface (48, 50) may have fins (44) aligned with a coolant flow (22). The fins may highest at mid-width of the near-wall inner surface. A two-sided cooling channel (36) may have two near-wall inner surfaces (48, 50) parallel to two respective exterior surfaces (40, 42), and may have an hourglass shaped transverse sectional profile. The tapered channel width (W1, W2) and the fin height profile (56A, 56B) increases cooling flow (22) into the corners (C) of the channel for more uniform and efficient cooling.

Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, and/or composition of matter configured for and/or resulting from, and/or a method for, activities that can comprise and/or relate to, investment casting a product in a mold, the product comprising at least one wall, the mold comprising a core, an inner primary shell, and an outer secondary shell.

Abstract: A cooling arrangement in a gas turbine system (120). The arrangement includes a plurality of flow network units (208) to transfer heat to cooling fluid, at least one unit including first (218), second (220), and third (222) flow sections between openings (64a) in a first wall (66) and an opening in a second wall (68) to pass cooling fluid through the walls. The first section includes first flow paths, between the openings in the first wall and the second section, extending to the second section. The third section includes third flow paths, between the second section and the opening in the second wall, to effect flow of cooling fluid. The second section includes one or more cooling fluid flow paths between the first section and the third section. The number of flow paths in the second section is fewer than the number of first flow paths and fewer than the number of third flow paths.

Abstract: A wall structure (32, 42, 68, 70, 80) with layers (A, B, C, D, E) of non-random voids (26A, 26B, 28B, 30B) that interconnect to form discretely defined tortuous passages between an interior (21) and an exterior surface (23) of the wall for transpiration cooling of the wall. A coolant flow (38) through the wall may be metered by restrictions in coolant outlets (31) and/or within the passages to minimize the coolant requirement. Pockets (44) may be formed on the exterior surface of the wall for thermal Insulation (46). The layers may be formed by lamination, additive manufacturing, or casting. Layer geometries include alternating layers (A, B, C) with different overlapping void patterns (42), 3-D lattice structures (70), and offset waffle structures (80).

Abstract: Certain exemplary embodiments can provide a composition, system, machine, device, manufacture, circuit, and/or user interface adapted for, and/or a method and/or machine-readable medium comprising machine-implementable instructions for, activities that can comprise, after removing a cast device from a stack-lamination-derived mold, said cast device formed from a molding composition, applying a desired shape to said cast device to form a shaped cast device, said molding composition comprising: a ceramic composition comprising silica; an cycloaliphatic epoxy binder composition, said cycloaliphatic epoxy binder composition present in said molding composition in an amount up to 30% by weight of said molding composition; a silicone composition comprising a siloxane resin, said silicone composition present in said molding composition in an amount up to 30% by weight of said molding composition; and a solvent composition adapted to dissolve said cycloaliphatic epoxy binder composition and said silicone composition.

Abstract: An investment casting process for a hollow component such as a gas turbine blade utilizing a ceramic core (10) that is cast in a flexible mold (24) using a low pressure, vibration assisted casting process. The flexible mold is cast from a master tool (14) machined from soft metal using a relatively low precision machining process, with relatively higher precision surfaces being defined by a precision formed insert (22) incorporated into the master tool. A plurality of identical flexible molds may be formed from a single master tool in order to permit the production of ceramic cores at a desired rate with a desired degree of part-to-part precision.

Abstract: A method of casting a component (42) having convoluted interior passageways (44). A desired three dimensional structure corresponding to a later-formed metal alloy component is formed by stacking a plurality of sheets (18, 20) of a fugitive material. The sheets contain void areas (22) corresponding to a desired interior passageway in the metal alloy component. A ceramic slurry material is cast into the three dimensional structure to form either a ceramic core (34) or a complete ceramic casting vessel (38). If just a ceramic core is formed, a wax pattern is formed around the ceramic core and an exterior ceramic shell (38) is formed around the wax pattern by a dipping process prior to the removal of the fugitive material and wax. An alloy component having the desired interior passageway is cast into the casting vessel after the fugitive material is removed.

Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.

Abstract: A hot gas path component (100) including: a metallic substrate (102) disposed beneath an outer surface (112) of the component (100) that is exposed to a hot gas present during operation of an internal combustion engine; a thermal barrier coating (TBC) (110) disposed on the metallic substrate (102) and defining a first portion (118) of the component outer surface (112); and a powder metallurgy structure (104) bonded to the metallic substrate (102) and in contact with the TBC (110).

Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.

Abstract: Certain exemplary embodiments can provide a composition, system, machine, device, manufacture, circuit, and/or user interface adapted for, and/or a method and/or machine-readable medium comprising machine-implementable instructions for, activities that can comprise, after removing a cast device from a stack-lamination-derived mold, said cast device formed from a molding composition, applying a desired shape to said cast device to form a shaped cast device, said molding composition comprising: a ceramic composition comprising silica; an cycloaliphatic epoxy binder composition, said cycloaliphatic epoxy binder composition present in said molding composition in an amount up to 30% by weight of said molding composition; a silicone composition comprising a siloxane resin, said silicone composition present in said molding composition in an amount up to 30% by weight of said molding composition; and a solvent composition adapted to dissolve said cycloaliphatic epoxy binder composition and said silicone composition.

Abstract: In certain exemplary embodiments of the present invention, three-dimensional micro-mechanical devices and/or micro-structures can be made using a production casting process. As part of this process, an intermediate mold can be made from or derived from a precision stack lamination and used to fabricate the devices and/or structures. Further, the micro-devices and/or micro-structures can be fabricated on planar or nonplanar surfaces through use of a series of production casting processes and intermediate molds. The use of precision stack lamination can allow the fabrication of high aspect ratio structures. Moreover, via certain molding and/or casting materials, molds having cavities with protruding undercuts also can be fabricated.

Abstract: Certain exemplary embodiments can provide a system, machine, device, manufacture, circuit, and/or composition of matter adapted for and/or resulting from, and/or a method for activities that can comprise and/or relate to, a first form comprising: a plurality of surface artifacts that substantially spatially replicate a surface geometry of a stacked foil mold; and a prong that is adapted to form a hole in a cast product.

Abstract: A continuous serpentine cooling circuit forming a progression of radial passages (44, 45, 46, 47A, 48A) between pressure and suction side walls (52, 54) in a MID region of a turbine airfoil (24). The circuit progresses first axially, then tangentially, ending in a last radial passage (48A) adjacent to the suction side (54) and not adjacent to the pressure side (52). The passages of the axial progression (44, 45, 46) may be adjacent to both the pressure and suction side walls of the airfoil. The next to last radial passage (47A) may be adjacent to the pressure side wall and not adjacent to the suction side wall. The last two radial passages (47A, 48A) may be longer along the pressure and suction side walls respectively than they are in a width direction, providing increased direct cooling surface area on the interiors of these hot walls.

Abstract: A serpentine cooling circuit (AFT) in a turbine airfoil (34A) starting from a radial feed channel (C1), and progressing axially (65) in alternating tangential directions through interconnected channels (C1, C2, C3) formed between partitions (T1, T2, J1). At least one of the partitions (T1, T2) has a T-shaped transverse section, with a base portion (67) extending from a suction or pressure side wall (64, 62) of the airfoil, and a crossing portion (68, 69) parallel to, and not directly attached to, the opposite pressure or suction side wall (62, 64). Each crossing portion bounds a near-wall passage (N1, N2) adjacent to the opposite pressure or suction side wall (62, 64). Each near-wall passage may have a smaller flow aperture area than one, or each, of two adjacent connected channels (C1, C2, C3). The serpentine circuit (AFT) may follow a forward cooling circuit (FWD) in the airfoil (34A).

Abstract: A cooling channel (36, 36B, 63-66) cools inner surfaces (48, 50) of exterior walls (41, 43) of a component (20, 60). Interior side surfaces (52, 54) of the channel converge to a waist (W2), forming an hourglass shaped transverse profile (46). The inner surfaces (48, 50) may have fins (44) aligned with the coolant flow (22). The fins may have a transverse profile (56A, 56B) highest at mid-width of the inner surfaces (48, 50). Turbulators (92) may be provided on the side surfaces (52, 54) of the channel, and may urge the coolant flow toward the inner surfaces (48, 50). Each turbulator (92) may have a peak (97) that defines the waist of the cooling channel. Each turbulator may have a convex upstream side (93). These elements increase coolant flow in the corners (C) of the channel to more uniformly and efficiently cool the exterior walls (41, 43).