Abstract: A counter-flow heat exchanger including a core region and a plenum region. The core region including a first set of heat exchanging passageways and a second set of heat exchanging passageways disposed at least partially therein. A plenum region is disposed adjacent opposed distal ends of the core region. Each of the plenum regions including a fluid inlet plenum, a fluid outlet plenum and a tube plate disposed therebetween. The first set of heat exchanging passageways is truncated and defines a first tube-side fluid flow path in a first direction. The second set of heat exchanging passageways defines a second tube-side fluid flow path in a second opposing direction. Each of the heat exchanging passageways extending from a fluid inlet plenum to a fluid outlet plenum. The tube plates and the core region include one of a cast metal formed thereabout each of the heat exchanging passageways or a braze bond formed between each of the heat exchanging passageways.

Abstract: Methods for creating a cast component, along with the resulting cast components, are provided. The method may provide for a controlled grain structure in the resulting cast component. The methods may include heating at least a first portion mold under controlled conditions, such as when the first portion of the mold is buried in a ceramic powder.

Abstract: A build assembly and a method of manufacturing the same are provided. The build assembly includes a first component, a second component, and a support structure coupling the two components together to fix their relative position. The support structure may be a “ghost” structure that is not connected with or does not contact the components, but is positioned such that the components are restrained to prevent distortion. The support structure may also be connected to the components and may define channels for removing additive powder from within or around the components.

Abstract: Methods for creating a cast component, along with the resulting cast components, are provided. The method may provide for a controlled grain structure in the resulting cast component. The methods may include heating at least a first portion mold under controlled conditions, such as when the first portion of the mold is buried in a ceramic powder.

Abstract: A counter-flow heat exchanger including a core region and a plenum region. The core region including a first set of heat exchanging passageways and a second set of heat exchanging passageways disposed at least partially therein. A plenum region is disposed adjacent opposed distal ends of the core region. Each of the plenum regions including a fluid inlet plenum, a fluid outlet plenum and a tube plate disposed therebetween. The first set of heat exchanging passageways is truncated and defines a first tube-side fluid flow path in a first direction. The second set of heat exchanging passageways defines a second tube-side fluid flow path in a second opposing direction. Each of the heat exchanging passageways extending from a fluid inlet plenum to a fluid outlet plenum. The tube plates and the core region include one of a cast metal formed thereabout each of the heat exchanging passageways or a braze bond formed between each of the heat exchanging passageways.

Abstract: The polishing system includes a power supply. The polishing system also includes a container including an interior portion. The interior portion includes a conductive material thereon. The conductive material is electrically coupled to the power supply. The polishing system also includes an electrolytic solution disposed within the container. The electrolytic solution includes a plurality of abrasive particles. The polishing system further includes a flexible media disposed within the container. The container is configured to contain an object. The power supply configured to electrically couple to the object. Each of the electrolytic solution, the flexible media, and the abrasive particles is configured to partially polish the object substantially simultaneously.

Abstract: A build assembly and a method of manufacturing the same are provided. The build assembly includes a first component, a second component, and a support structure coupling the two components together to fix their relative position. The support structure may be a “ghost” structure that is not connected with or does not contact the components, but is positioned such that the components are restrained to prevent distortion. The support structure may also be connected to the components and may define channels for removing additive powder from within or around the components.

Abstract: The polishing system includes a power supply. The polishing system also includes a container including an interior portion. The interior portion includes a conductive material thereon. The conductive material is electrically coupled to the power supply. The polishing system also includes an electrolytic solution disposed within the container. The electrolytic solution includes a plurality of abrasive particles. The polishing system further includes a flexible media disposed within the container. The container is configured to contain an object. The power supply configured to electrically couple to the object. Each of the electrolytic solution, the flexible media, and the abrasive particles is configured to partially polish the object substantially simultaneously.

Abstract: A method involves filling a hydrogen-lean molten material in a crucible and closing a lid of the crucible and then feeding a first quantity of a compressed dry gas via the crucible to form a dry gas blanket on a surface of the hydrogen-lean molten material. The method further involves feeding a second quantity of the compressed dry gas to a mold assembly to purge the mold assembly and transferring the hydrogen-lean molten material via an opening of the lid of the crucible to a mold cavity of the mold assembly. The method further involves cooling the hydrogen-lean molten material to form a casting.

Abstract: Shell molds and processes for making the shell molds that exhibit high emissivity in the red and infrared regions. In this manner, thermal resistance within a gap formed between solidifying cast metal and the interior mold surface is decreased. In one embodiment, the facecoat region is formed from a slurry composition comprising an aluminum oxide, a green chromium oxide and a silicon dioxide. In another embodiment, the facecoat region is formed from a slurry composition including zirconium silicate and silica with stucco layer of alumina is included.

Abstract: Shell molds and processes for making the shell molds that exhibit high emissivity in the red and infrared regions. In this manner, thermal resistance within a gap formed between solidifying cast metal and the interior mold surface is decreased. In one embodiment, the facecoat region is formed from a slurry composition comprising an aluminum oxide, a green chromium oxide and a silicon dioxide. In another embodiment, the facecoat region is formed from a slurry composition including zirconium silicate and silica with stucco layer of alumina is included.

Abstract: Shell molds and processes for making the shell molds that exhibit high emissivity in the red and infrared regions. In this manner, thermal resistance within a gap formed between solidifying cast metal and the interior mold surface is decreased. In one embodiment, the facecoat region is formed from a slurry composition comprising an aluminum oxide, a green chromium oxide and a silicon dioxide. In another embodiment, the facecoat region is formed from a slurry composition including zirconium silicate and silica with stucco layer of alumina is included.

Abstract: Processes for directionally casting liquid metal to form an articles can include compressing a seal intermediate a mold chill plate and a mold assembly, wherein the seal circumscribes a shell mold in the mold assembly; filling the shell mold in the mold assembly with molten metal; immersing the mold assembly into a liquid metal cooling bath from a bottom portion to a top portion of the mold assembly; and transmitting heat from the mold assembly to the liquid metal cooling bath to solidify the molten metal from the bottom portion to the top portion of the mold assembly.

Abstract: An apparatus for directionally casting articles generally includes a seal between a mold assembly and chill plate. In one embodiment, the mold assembly includes a skirt laterally extending from at least one shell mold, wherein the skirt includes a channel disposed in a bottom surface that is configured to surround the at least one shell mold. A chill plate fastened to a bottom of the mold assembly and includes a boss having a shape complementary to the channel, wherein the boss of the chill plate is seated within the channel of the mold assembly to define the seal about the at least one shell mold.

Abstract: A method of assembling a turbine bucket is provided. The bucket includes a dovetail portion, an airfoil portion, and a root that extends between the airfoil portion and the dovetail portion. The turbine bucket includes a pressure side and a suction side that are connected together at a leading edge and a trailing edge. The method includes forming at least one pocket within the turbine bucket, such that the pocket is formed within the pressure side. The method also includes forming at least one pin within the at least one pocket.

Abstract: A method of assembling a turbine bucket is provided. The bucket includes a dovetail portion, an airfoil portion, and a root that extends between the airfoil portion and the dovetail portion. The turbine bucket includes a pressure side and a suction side that are connected together at a leading edge and a trailing edge. The method includes forming at least one pocket within the turbine bucket, such that the pocket is formed within the pressure side. The method also includes forming at least one pin within the at least one pocket.

Abstract: A mold assembly for a liquid metal cooled directional solidification furnace having a cooling chamber provided with liquid metal and a heating chamber includes a mold member having a main body portion that defines an interior mold cavity. The mold member is adapted to be positioned in the heating chamber. The mold assembly also includes a chill-plate formed from a material having a thermal diffusivity a 600° K greater than approximately 10 E-6 m2/s, inert to at least one of molten tin and molten aluminum and adapted to be at least partially immersed in the liquid metal. The chill-plate includes a main body portion having a first surface extending to a second surface through an intermediate portion. The chill-plate is adapted to establish a thermal gradient between the mold member and the heating chamber.