Abstract: The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: A method is provided for casting a component. Accordingly, a casting core is provided within a cavity of a component mold. The casting core defines an inner component shape and includes a core wall. The core wall defines a core outer surface and a core inner surface disposed opposite the core outer surface. The core inner surface defines a core cavity. The casting core also includes a removal facilitation feature. The component is cast within the cavity of the component mold with the casting core positioned therein. The cast component is removed from the component mold and the casting core is removed from the cast component.

Abstract: A method for additively manufacturing components includes additively printing a metallic preform such that the preform contains a predetermined amount of porosity. Furthermore, the method includes working the additively printed preform such that the preform incurs a predetermined amount of deformation. Moreover, the method includes heat treating the worked preform to form a final component.

Abstract: Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Abstract: A method is provided for casting a component. Accordingly, a casting core is provided within a cavity of a component mold. The casting core defines an inner component shape and includes a core wall. The core wall defines a core outer surface and a core inner surface disposed opposite the core outer surface. The core inner surface defines a core cavity. The casting core also includes a removal facilitation feature. The component is cast within the cavity of the component mold with the casting core positioned therein. The cast component is removed from the component mold and the casting core is removed from the cast component.

Abstract: A nickel-based superalloy is provided, which includes: 5.6 wt % to 6.6 wt % aluminum; 6.0 wt % to 9.0 wt % tantalum; 4.0 wt % to 7.0 wt % chromium; 4.0 wt % to 7.0 wt % tungsten; 0.5 wt % to 2.5 wt % molybdenum; 1.5 wt % to 5.5 wt % rhenium; 7.0 wt % to 13.0 wt % cobalt; 0.1 wt % to 0.7 wt % hafnium; 0.001 wt % to 0.005 wt % carbon; 0.002 wt % to 0.05 wt % boron; up to 0.1 wt % yttrium; and a balance of nickel and incidental impurities, wherein the composition exhibits a rupture life that is greater than 80 hours at 1093.3° C. and 20 ksi and an oxidation resistance of less than 25.4 ?m surface loss at 1176.7° C. after a 400 hour Mach I test. Components are also provided formed from such a nickel-based superalloy.

Abstract: A nickel-based superalloy composition is provided that includes 6.1 wt. % to 6.6 wt. % aluminum; 5.6 wt. % to 6.6 wt. % tantalum; 9.0 wt. % to 11.0 wt. % chromium; 5.5 wt % to 6.2 wt. % tungsten; 1.1 wt. % to 1.4 wt % molybdenum; 2.0 wt. % to 2.6 wt % rhenium; 5.5 wt. % to 10.0 wt % cobalt; 0.2 wt % to 0.5 wt % hafnium; up to 0.05 wt % carbon; 0.002 wt % to 0.01 wt % boron; and a balance of nickel and incidental impurities, wherein the composition exhibits a rupture life that is greater than 40 hours at 982.2° C. and 40 ksi, and wherein the composition exhibits a corrosion resistance of less than 50.8 ?m attack at 926.7° C. after a 940 hour burner rig test. Components are also provided formed from the composition.

Abstract: A method for additively manufacturing components includes additively printing a metallic preform such that the preform contains a predetermined amount of porosity. Furthermore, the method includes working the additively printed preform such that the preform incurs a predetermined amount of deformation. Moreover, the method includes heat treating the worked preform to form a final component.

Abstract: Methods for direct writing of single crystal super alloys and metals are provided. The method can include: heating a substrate positioned on a base plate to a predetermined temperature using a first heater; using a laser to form a melt pool on a surface of the substrate; introducing a superalloy powder to the melt pool; measuring the temperature of the melt pool; receiving the temperature measured at a controller; and using an auxiliary heat source in communication with the controller to adjust the temperature of the melt pool. The predetermined temperature is below the substrate's melting point. The laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition. An apparatus is also generally provided for direct writing of single crystal super alloys and metals.

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: Cast components are provided that include a first section comprising a first metal material and having first grains with a first average grain size and a second section comprising a second metal material and having second grains with a second average grain size.

Abstract: A method of forming a cast component and a method of forming a casting mold is described herein. The ceramic core-shell mold includes at least first core portion, a first shell portion, and at least one first cavity between the core portion and the first shell portion. The core-shell mold may be manufactured using an additive manufacturing process and may include an integrated ceramic filter. At least a portion of the ceramic core-shell mold and the wax gate component is coated with a second ceramic material. The wax gate component is then removed to form a second cavity in fluid communication with the first cavity.

Abstract: An engine component for a turbine engine, the engine component comprising a wall bounding an interior; a panel portion defining a portion of the wall, the panel portion comprising: an outer wall; an inner wall spaced from the outer wall to define a wall gap; and a structural segment formed within the wall gap comprising at least one structural element. The apparatus formed from a method including calculating a factor and adjusting a variable until the factor is between a given range.

Abstract: Methods for creating a cast component, along with the resulting cast components, are provided. The method may include heating a mold having a cavity therein; supplying a first molten metal material into the cavity of the mold such that the first molten metal material is directed to a first portion of the cavity of the mold; supplying a second molten metal material into the cavity of the mold such that the second molten metal material is directed to a second portion of the cavity of the mold, wherein the first molten metal material is compositionally different than the second molten metal material; and thereafter, allowing the first molten metal material and the second molten metal material to form the cast component.

Abstract: An apparatus and method for forming an engine component for a turbine engine, the engine component comprising a wall bounding an interior; a panel portion defining a portion of the wall, the panel portion comprising: an outer wall; an inner wall spaced from the outer wall to define a wall gap; and a structural segment formed within the wall gap comprising at least one structural element. The method including calculating a factor and adjusting a variable until the factor is between a given range.

Abstract: The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: An apparatus and method for forming an engine component for a turbine engine, the engine component comprising a wall bounding an interior; a panel portion defining a portion of the wall, the panel portion comprising: an outer wall; an inner wall spaced from the outer wall to define a wall gap; and a structural segment formed within the wall gap comprising at least one structural element. The method including calculating a factor and adjusting a variable until the factor is between a given range.

Abstract: A method for additively manufacturing components includes additively printing a metallic preform such that the preform contains a predetermined amount of porosity. Furthermore, the method includes working the additively printed preform such that the preform incurs a predetermined amount of deformation. Moreover, the method includes heat treating the worked preform to form a final component.

Abstract: Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Abstract: A method is provided for casting a component. Accordingly, a casting core is provided within a cavity of a component mold. The casting core defines an inner component shape and includes a core wall. The core wall defines a core outer surface and a core inner surface disposed opposite the core outer surface. The core inner surface defines a core cavity. The casting core also includes a removal facilitation feature. The component is cast within the cavity of the component mold with the casting core positioned therein. The cast component is removed from the component mold and the casting core is removed from the cast component.