Abstract: The present disclosure relates to a method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a filter, 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 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: The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud. The disclosure also relates to the forming of a ceramic coating on at least a portion of the shell of the core-shell casting mold.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade, stator vane, or shroud. The disclosure also relates to the forming of a ceramic coating on at least a portion of the shell of the core-shell casting mold.

Abstract: The present disclosure relates to a method of forming a cast component and a method of forming a casting mold. The method is performed by connecting at least one wax gate component to a ceramic core-shell mold. The ceramic core-shell mold includes at least a first core portion, a first shell portion, and a second shell portion, wherein the first shell portion is adapted to interface with at least the second shell portion to form at least one first cavity between the core portion and the first and second shell portions. The core-shell mold may be inspected and assembled prior to connection of the wax gate component. 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: A coating system disposed on a surface of a substrate is provided. The coating system may include a bond coating layer on the surface of the substrate, a dense TBC layer on the bond coating layer, and a columnar TBC layer on the dense TBC layer, with the columnar TBC layer defines a plurality of elongated surface-connected voids. The dense TBC layer generally includes a ceramic material and has a porosity of about 15% or less. A method is also provided for forming a coating system on a surface of a substrate.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade or stator vane, which provide 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: The present disclosure generally relates to integrated core-shell investment casting molds including a main core portion, a core tip portion, and a shell portion with at least one cavity between the core portion and the shell portion. The cavity defines the shape of a cast component upon casting and removal of the ceramic mold. These molds also provide filament structures corresponding to cooling hole patterns in the surface of the turbine blade or the stator vane, which provide a leaching pathway for the core portion after metal casting. At least two ceramic tip filaments connect the core tip portion and the shell portion and eliminate the need for tip pins or a shell lock to hold the tip plenum core in place during 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 of casting a truss structure having spaced face sheets connected by columnar structures, including forming a three-dimensional pattern (3D pattern) in the shape of the truss structure with the spaced face sheets and columnar structures, forming a mold core of the 3D pattern by surrounding the pattern with a liquid and letting the liquid harden about the 3D pattern, removing the 3D pattern from the mold core, filling the mold core with a liquid alloy to cast and directionally solidify the truss structure.

Abstract: Methods are provided for forming a thermal barrier coating system on a surface of a component. The method can include introducing the component into a coating chamber, where a first ceramic source material and a second ceramic source material are positioned within the coating chamber of a physical vapor deposition apparatus. An energy source is directed onto the first ceramic source material to vaporize the first ceramic source material to deposit a first layer on the component. The energy source is alternated between the first ceramic source material and the second ceramic source material to form a blended layer on the first layer.

Abstract: A thermal barrier coating system is disclosed.

Abstract: A method and apparatus for minimizing engine weight for a turbine engine by utilizing one or more discrete protuberances disposed on an engine component wall. The wall can have a nominal thickness to decrease engine weight while the protuberances can provide increased discrete thicknesses for providing one or more cooling holes. The increased thickness at the protuberances provides for an increased thickness to provide sufficient length to increase cooling hole effectiveness.

Abstract: The present disclosure generally relates to casting molds including a casting shell surrounding at least a portion of a casting core comprising a first metal component and a hot isostactic pressed second metal component around the first metal component. In one aspect, the first metal component may have a lower melting point than the second metal component. In another aspect, the second metal component may retain some metal powder grain structure.

Abstract: The present disclosure generally relates to casting molds including a casting core comprising a first metal component and a second metal component. In an aspect, the first metal component has a lower melting point than the second metal component. In another aspect, the second metal component surrounds at least a portion of the first metal component and defines a cavity in the casting core when the first metal component is removed and the second metal component is not removed.

Abstract: The present disclosure generally relates to investment casting molds comprising a casting core comprising at least one graded core component, the graded core component comprising at least one graded transition between a first core material and a second core material.