Abstract: A gas turbine airfoil having internal cooling passages is formed by additive manufacturing. Layers of superalloy powder are fused by an energy beam using a two-dimensional pattern providing unmelted areas forming passageways therein. Layers of the powder are added and fused using sufficient two-dimensional patterns to form the entire airfoil with the desired pattern of internal cooling passages. After completion of the formation of the airfoil, it may be hot isostatic pressed, directionally recrystallized, bond coated, and covered with a thermal barrier layer.

Abstract: A method of forming a complex shaped part includes the steps of forming a polymer core by an additive manufacturing process. A metal is plated about surfaces of the polymer core, and the polymer core is removed, leaving hollows within a plate core. Metal powder is deposited within the hollows. An integral blade rotor is also disclosed.

Abstract: A method of component forming according to an exemplary aspect of the present disclosure includes, among other things, positioning a metal powder in a mold cavity, melting the metal powder within the mold cavity, and cooling the melted metal powder to form a component.

Abstract: An airfoil includes an airfoil body that defines a longitudinal axis. The airfoil body includes a leading edge and a trailing edge and a first side wall and a second side wall that is spaced apart from the first side wall. The first side wall and the second side wall join the leading edge and the trailing edge and at least partially define a cavity in the airfoil body. A lattice network connects the first side and the second side. The lattice network includes at least one enlarged node spaced apart from the first side wall and the second side wall and ribs that extend from the at least one enlarged node. Each of the ribs connects to one of the first side wall and the second side wall.

Abstract: An example multi-dimensional component building system includes a first chamber having at least one base, a second chamber adjacent to and in fluid communication with the first chamber through a first door, and a third chamber adjacent to and in fluid communication with the second chamber through a second door. The second chamber is fluidly sealed from the first chamber if the first door is in a closed position. The second chamber includes a directed heat source, a build-up material and is configured to receive the at least one base if the fluid parameters of the first chamber and second chamber are approximately equal. The third chamber is fluidly sealed from the second chamber if the first door is in a closed position. The third chamber is configured to receive the at least one base, having a formed component disposed thereon, if the second door is in an open position.

Abstract: A method of manufacturing a casting article for use in a casting process includes rapidly forming the casting article out of a metallic material. A ceramic coating is applied to an exterior surface of the casting article.