Abstract: The present disclosure generally relates to casting molds including a casting core comprising an outer shell mold surrounding at least a portion of a casting core and a casting core comprising a second metal skin layer around a first metal component. In one aspect, at least one portion of the first metal component may be exposed on a surface of the outer shell mold. In another aspect, the outer shell mold may be configured to define a cavity in the casting core when the first metal component is removed and the second metal skin layer is not removed.

Abstract: An apparatus and method for an airfoil for a gas turbine engine includes a trailing edge cooling circuit utilizing a plurality of trailing edge ejection holes. The ejection holes can include a circumferentially radiused inlet, a converging section, a metering section, and a diverging section to improve airfoil cooling as well as castability.

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: 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: Apparatus and methods for direct writing of single crystal super alloys and metals are provided. In one method, a substrate is heated to a pretermined temperature below its melting point, and a laser is used to form a melt pool on a surface of a substrate. The substrate is positioned on a base plate, and the laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition and the substrate is heated to a temperature below its melting point. A superalloy powder is introduced to the melt pool, and the temperature of the melt pool is controlled to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate.

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: Coating systems and processes by which the coating systems can be deposited to be resistant to contaminants, and particularly resistant to infiltration and damage caused by CMAS. The coating systems include inner and outer ceramic layers. The inner ceramic layer consists essentially of zirconia stabilized by about 6 to about 9 weight percent yttria and optionally contains greater than 0.5 to 10 weight percent hafnium oxide. The outer ceramic layer overlies and contacts the inner ceramic layer to define the outermost surface of the coating system. The outer ceramic layer consists essentially of zirconia stabilized by about 25 to about 75 weight percent yttria, has a thickness that is less than the thickness of the inner ceramic layer and further contains greater than 0.5 to 10 weight percent hafnium oxide and optionally 1 to 10 weight percent tantalum oxide. The outer ceramic layer has a porosity level that is lower than that of the inner ceramic layer.

Abstract: A nickel-based superalloy composition includes from about 5 to about 7 wt % aluminum, from about 4 to about 8 wt % tantalum, from about 3 to about 8 wt % chromium, from about 3 to about 7 wt % tungsten, from 1 to about 5 wt % molybdenum, from 1.5 to about 5 wt % rhenium, from 5 to about 14 wt % cobalt, from about 0 to about 1 wt % hafnium, from about 0.01 to about 0.03 wt % carbon, from about 0.002 to about 0.006 wt % boron, and balance nickel and incidental impurities. The composition may exhibit a sustained peak low cycle fatigue life at 1800° F./45 ksi of at least about 4000 cycles. The nickel-based superalloy composition may be used in single-crystal or directionally solidified superalloy articles, such as a blade, nozzle, a shroud, a splash plate, and a combustor of a gas turbine engine.

Abstract: A nickel-based superalloy composition includes from about 5 to about 7 wt % aluminum, from about 4 to about 8 wt % tantalum, from about 3 to about 8 wt % chromium, from about 3 to about 7 wt % tungsten, from 1 to about 5 wt % molybdenum, from 1.5 to about 5 wt % rhenium, from 5 to about 14 wt % cobalt, from about 0 to about 1 wt % hafnium, from about 0.01 to about 0.03 wt % carbon, from about 0.002 to about 0.006 wt % boron, and balance nickel and incidental impurities. The composition may exhibit a sustained peak low cycle fatigue life at 1800° F./45 ksi of at least about 4000 cycles. The nickel-based superalloy composition may be used in single-crystal or directionally solidified superalloy articles, such as a blade, nozzle, a shroud, a splash plate, and a combustor of a gas turbine engine.

Abstract: Coating systems and processes by which the coating systems can be deposited to be resistant to contaminants, and particularly resistant to infiltration and damage caused by CMAS. The coating systems include inner and outer ceramic layers. The inner ceramic layer consists essentially of zirconia stabilized by about 6 to about 9 weight percent yttria and optionally contains greater than 0.5 to 10 weight percent hafnium oxide. The outer ceramic layer overlies and contacts the inner ceramic layer to define the outermost surface of the coating system. The outer ceramic layer consists essentially of zirconia stabilized by about 25 to about 75 weight percent yttria, has a thickness that is less than the thickness of the inner ceramic layer and further contains greater than 0.5 to 10 weight percent hafnium oxide and optionally 1 to 10 weight percent tantalum oxide. The outer ceramic layer has a porosity level that is lower than that of the inner ceramic layer.

Abstract: A nickel-based superalloy composition includes from about 5 to about 7 wt % aluminum, from about 4 to about 8 wt % tantalum, from about 3 to about 8 wt % chromium, from about 3 to about 7 wt % tungsten, from 1 to about 5 wt % molybdenum, from 1.5 to about 5 wt % rhenium, from 5 to about 14 wt % cobalt, from about 0 to about 1 wt % hafnium, from about 0.01 to about 0.03 wt % carbon, from about 0.002 to about 0.006 wt % boron, and balance nickel and incidental impurities. The composition may exhibit a sustained peak low cycle fatigue life at 1800° F./45 ksi of at least about 4000 cycles. The nickel-based superalloy composition may be used in single-crystal or directionally solidified superalloy articles, such as a blade, nozzle, a shroud, a splash plate, and a combustor of a gas turbine engine.

Abstract: A process of fabricating a rotating component and a rotating component formed thereby. The rotating component has a rotational axis, at least one rim member, at least one disk member, and at least one airfoil member. The rim and disk members are welded together to define a first solid-state weld joint lying in a first plane that is not parallel to the rotational axis of the rotating component. The airfoil member is welded to the rim member to define a second solid-state weld joint lying in a second plane that is not parallel to the rotational axis of the rotating component. The rim member is located in a radially outward direction from the disk member, and the airfoil member is located in a radially outward direction from the rim member.

Abstract: A process of fabricating a rotating component and components formed thereby. The process includes fabricating preforms corresponding to portions of the component. Each preform has an interface surface at which the preforms can be joined to locate a first of the portions in a radially outward direction from a second of the portions. The preforms are then inertia welded together to form a profile having a solid-state weld joint containing a finer-grained material than other portions of the profile. The profile is then forged with dies to produce a forging. At least one of the dies has a recess into which the finer-grained material from the weld joint is expelled during forging to purge a joint region of the forging between the forging portions of the finer-grained material. The joint region contains grains distorted in an axial direction of the forging.

Abstract: An airfoil for a gas turbine engine is provided that includes a first sidewall and a second sidewall coupled together at a leading edge and a trailing edge, such that a cavity is defined therebetween. A central plenum and an impingement chamber are defined within the cavity. The central plenum channels cooling fluid to the impingement chamber where cooling fluid impinges on the sidewalls. Cooling fluid is discharged from the impingement chamber via film cooling holes.

Abstract: Gas turbine engine compressor disks having a hot flowpath side; a shaft having a first surface positioned in the hot flowpath side; and a thermal barrier applied to at least the first surface of the shaft where the thermal barrier is operable to maintain the temperature of the shaft below about 700° C. (1300° F.) when the hot flowpath side experiences a service operating temperature of from about 700° C. (1300° F.) to about 788° C. (1450° F.).

Abstract: A process of fabricating a rotating component and a rotating component formed thereby. The rotating component has a rotational axis, at least one rim member, at least one disk member, and at least one airfoil member. The rim and disk members are welded together to define a first solid-state weld joint lying in a first plane that is not parallel to the rotational axis of the rotating component. The airfoil member is welded to the rim member to define a second solid-state weld joint lying in a second plane that is not parallel to the rotational axis of the rotating component. The rim member is located in a radially outward direction from the disk member, and the airfoil member is located in a radially outward direction from the rim member.

Abstract: A process of fabricating a rotating component and components formed thereby. The process includes fabricating preforms corresponding to portions of the component. Each preform has an interface surface at which the preforms can be joined to locate a first of the portions in a radially outward direction from a second of the portions. The preforms are then inertia welded together to form a profile having a solid-state weld joint containing a finer-grained material than other portions of the profile. The profile is then forged with dies to produce a forging. At least one of the dies has a recess into which the finer-grained material from the weld joint is expelled during forging to purge a joint region of the forging between the forging portions of the finer-grained material. The joint region contains grains distorted in an axial direction of the forging.

Abstract: A turbine blade having an internal skeleton having a plurality of internal ribs that form a plurality of open cooling channels; an internal environmental coating applied to the internal skeleton; an outer wall applied about the open cooling channels of the internal skeleton to form a near wall circuit of cooling channels; and an external environmental coating applied to the outer wall wherein the internal environmental coating is different from the external environmental coating.

Abstract: Methods for making a turbine blade involving casting an internal skeleton having a plurality of internal ribs which form a plurality of open cooling channels, applying a filler material to the open cooling channels, and applying an outer wall about the internal skeleton having the filler material applied to the open cooling channels.

Abstract: A superalloy composition comprising, in weight percent: about 6.2-6.6 Al, about 6.5-7.0 Ta, about 6.0-7.0 Cr, about 6.25-7.0 W, about 1.5-2.5 Mo, about 0.15-0.60 Hf, 0.0-1.0 Re, 6.5-9.0 Co, optionally, 0.03-0.06 C, optionally, up to about 0.004 B, optionally up to about 0.03 total of one or more rare earth elements selected from yttrium (Y), lanthanum (La), or cerium (Ce), balance nickel, such that the superalloy composition exhibits a stress rupture capability improvement of at least 15% over a base stress rupture capability of a base composition nominally comprising, in weight percent: 6.5 Al, 6.6 Ta, 6.0 Cr, 6.25 W, 1.5 Mo, 0.15 Hf, 0.0 Re, 7.5 Co. Articles incorporating the superalloy composition include a gas turbine engine component such as a high pressure turbine nozzle or nozzle segment.