Abstract: Delamination of thermal barrier coatings (“TBC's”) (276) from superalloy substrates (262) of components (260) for turbine engines (80), such as engine blades (92), vanes (104, 106), or castings in transitions (85), is inhibited during subsequent cooling passage (270) formation. Partially completed cooling passages (264), which have skewed passage paths that end at a terminus (268), which is laterally offset from the passage entrance (266), are formed in the superalloy component (260) prior to application of the TBC layer(s) (276). The skewed, laterally offset path of each partially completed cooling passage (264) establishes an overhanging shield layer (269) of superalloy material that protects the TBC layer (276) during completion of the cooling passage (270).

Abstract: Delamination of thermal barrier coatings (“TBC's”) (276) from superalloy substrates (262) of components (260) for turbine engines (80), such as engine blades (92), vanes (104, 106), or castings in transitions (85), is inhibited during subsequent cooling passage (270) formation. Partially completed cooling passages (264), which have skewed passage paths that end at a terminus (268), which is laterally offset from the passage entrance (266), are formed in the superalloy component (260) prior to application of the TBC layer(s) (276). The skewed, laterally offset path of each partially completed cooling passage (264) establishes an overhanging shield layer (269) of superalloy material that protects the TBC layer (276) during completion of the cooling passage (270).

Abstract: Cooling passages (99, 105) are formed in components for combustion turbine engines, such as blades (92), vanes (104, 106), ring segments (110) or castings in transitions (85), during investment casting, through use of ceramic shell inserts (130) within the casting mold (152). Ceramic posts (134) formed in the ceramic shell insert (130) have profiles conforming to corresponding profiles of partially completed cooling passages (156). Posts (134) are removed after superalloy component casting, forming the partially completed cooling passages, which are subsequently completed by removing remaining superalloy material along the cooling passage path.

Abstract: A thermal barrier tile (34) with a braze layer (46) co-sintered to a ceramic layer (48), optionally with a layer of MCrAlY bond material (74) disposed there between. The tile can be brazed to a substrate (26) of a component for fabrication or repair of a thermal barrier coating (28). The tile may be fabricated by disposing a first layer of a metal brazing material in a die case (40); disposing a second layer of a ceramic powder on the metal brazing material; and co-sintering the two layers with spark plasma sintering to form the co-sintered ceramic/metal tile. The tile may include an interlocking structural pattern (56) at the ceramic/braze interface, and further may include mirror image contoured edges (70) for interlocking of tiles that are disposed side-by-side. Heights of adjacent tiles (34F, 34G) may be different to improve abradability of the surface.