Abstract: A molding tool (10) for manufacturing cooling features in a ceramic core for a casting process includes a first mold portion (12) comprising a crossover hole forming feature (18); a second mold portion (24) comprising an impingement jet receiving forming feature (30) for forming an impingement jet receiving feature having a desired aiming point (32); and a sacrificial alignment member (34) for extending at least partially into the crossover hole forming feature (18) at least partially into the aiming point (32) of the impingement jet receiving forming feature (30) for substantially aligning a central axis (38) of the crossover hole forming feature (18) with the aiming point (32) to maintain a crossover hole and aiming point alignment during casting to ensure that the jet is directed at the aiming point (32) in a resultant cast part.

Abstract: A method of manufacturing a substrate (16) with a ceramic thermal barrier coating (28, 32). The interface between layers of the coating contains an engineered surface roughness (12, 24) to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold (10,20) and is infused by a subsequently cast layer of material (16, 28). The substrate may be partially sintered (76) prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer.

Abstract: A method for producing a flexible mold for casting a ceramic core, the ceramic core used for an investment casting, is presented. The method includes forming a consumable master tool by 3D-printing, producing the flexible mold from the master tool, allowing the flexible mold to cure, and removing the consumable master tool. The master tool includes a negative surface geometry representative of the flexible mold to be produced.

Abstract: A method of manufacturing a tooling assembly and the tooling assembly (10) for ceramic cores. The tooling assembly includes a backing plate (12) comprising a top surface (20), side surfaces (18), and a bottom surface (16) and a plurality of lithographically derived inserts (14) each having a bottom surface (24), side surfaces (26), and a positive top surface (28) and pieced together on the top surface (20) of the backing plate (12). The method includes providing the backing plate (12) and plurality of lithographically derived inserts (14). A non-conformal positive surface is generated from the plurality of lithographically derived inserts (14). A negative flexible mold is created from the non-conformal positive surface. The negative flexible mold is then prepared for casting for an advanced ceramic core.

Abstract: A ceramic core (40) for an investment casting process (80) including a subsurface internal channel (50) for the introduction of leachate (98) to improve the effectiveness of a leaching process used to remove the core (94) from a cast alloy component (100). The subsurface internal channel may be completely hollow, or it may include one or more ribs (54). The core may be formed (82) using a 3D printing process wherein a carrier material (68) is deposited in a central region of the channel for the purpose of supporting an overlying layer (62) of core material, with the carrier material later being removed to reveal the hollow internal channel (52).

Abstract: An investment casting core (10) incorporates an alignment guide (24) extending through a body (12) of the core. The alignment guide (24) defines a coolant flow path (92) in a later-cast metal component (76) extending from a coolant outlet opening (90) in an impingement structure (88) to an impingement target area (86) of a cooling feature (84) formed on an impingement cooled surface (82) of the component (76). Methods of making the core (10) and using the core (10) in lost wax investment casting processes are also described.

Abstract: A molding tool (10) for manufacturing cooling features in a ceramic core for a casting process includes a first mold portion (12) comprising a crossover hole forming feature (18); a second mold portion (24) comprising an impingement jet receiving forming feature (30) for forming an impingement jet receiving feature having a desired aiming point (32); and a sacrificial alignment member (34) for extending at least partially into the crossover hole forming feature (18) at least partially into the aiming point (32) of the impingement jet receiving forming feature (30) for substantially aligning a central axis (38) of the crossover hole forming feature (18) with the aiming point (32) to maintain a crossover hole and aiming point alignment during casting to ensure that the jet is directed at the aiming point (32) in a resultant cast part.

Abstract: A component is provided and includes a core including a ceramic matrix composite material, one or more cooling channels formed about the core, an outer metal shell disposed about the core and the one or more cooling channels and a protective material between the core and the outer metal shell. The one or more cooling channels are formed about the core as an array of cooling channels in the protective material.

Abstract: A method of manufacturing a substrate (16) with a ceramic thermal barrier coating (28, 32). The interface between layers of the coating contains an engineered surface roughness (12, 24) to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold (10,20) and is infused by a subsequently cast layer of material (16, 28). The substrate may be partially sintered (76) prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer.

Abstract: A method of manufacturing a tooling assembly and the tooling assembly (10) for ceramic cores. The tooling assembly includes a backing plate (12) comprising a top surface (20), side surfaces (18), and a bottom surface (16) and a plurality of lithographically derived inserts (14) each comprising a bottom surface (24), side surfaces (26), and a positive top surface (28) and pieced together on the top surface (20) of the backing plate (12). The method includes providing the backing plate (12) and plurality of lithographically derived inserts (14). A non-conformal positive surface is generated from the plurality of lithographically derived inserts (14). A negative flexible mold is created from the non-conformal positive surface. The negative flexible mold is then prepared for casting for an advanced ceramic core.

Abstract: A method of manufacturing a substrate (16) with a ceramic thermal barrier coating (28, 32). The interface between layers of the coating contains an engineered surface roughness (12, 24) to enhance the mechanical integrity of the bond there between. The surface roughness is formed in a surface of a mold (10,20) and is infused by a subsequently cast layer of material (16, 28). The substrate may be partially sintered (76) prior to application of the coating layer(s) and the coated substrate and coating layer(s) may be co-sintered to form a fully coherent strain-free interlayer.

Abstract: A method of manufacturing protruding cast in features (10). At least one core insert (12) is manufactured using small particle sizes. A bulk core body is manufactured using large particle sizes. The at least one core insert (12) and bulk core body are fully fired separately. The at least one core insert (12) is bonded with the bulk core body.

Abstract: A method of manufacturing a tooling assembly and the tooling assembly (10) for ceramic cores. The tooling assembly includes a backing plate (12) comprising a top surface (20), side surfaces (18), and a bottom surface (16) and a plurality of lithographically derived inserts (14) each comprising a bottom surface (24), side surfaces (26), and a positive top surface (28) and pieced together on the top surface (20) of the backing plate (12). The method includes providing the backing plate (12) and plurality of lithographically derived inserts (14). A non-conformal positive surface is generated from the plurality of lithographically derived inserts (14). A negative flexible mold is created from the non-conformal positive surface. The negative flexible mold is then prepared for casting for an advanced ceramic core.

Abstract: A method of manufacturing protruding cast in features (10). At least one core insert (12) is manufactured using small particle sizes. A bulk core body is manufactured using large particle sizes. The at least one core insert (12) and bulk core body are fully fired separately. The at least one core insert (12) is bonded with the bulk core body.

Abstract: A hard tool configuration and method of manufacturing advanced detailed trailing edge features in a core for casting. The hard tool configuration includes at least a first platform and a second platform. The hard tool configuration also includes a first end of a plurality of removable rake elements removably attached to at least one of the first platform and the second platform. The hard tool configuration also includes an internal mold geometry in a spacing in between the center facing side of the first platform and the center facing side of the second platform.

Abstract: A component is provided and includes a core including a ceramic matrix composite material, one or more cooling channels formed about the core, an outer metal shell disposed about the core and the one or more cooling channels and a protective material between the core and the outer metal shell. The one or more cooling channels are formed about the core as an array of cooling channels in the protective material.

Abstract: A turbine element for high pressure drop and heat transfer. The turbine element includes a plurality of elements (16) radially placed in columns together aligned in a series of rows of at least four rows across an interior surface of an outer wall of an airfoil (10), creating a pin fin pattern (14) based on the shape of each of the plurality of elements (16), wherein each element (16) includes an inner length between an inner top edge and an inner bottom edge, an inner width between an inner left edge and an inner right edge. The pin fin pattern (14) is highly packed and fills a portion of the interior surface of the outer wall of the airfoil (10).

Abstract: A process for forming a component is provided. The process includes providing a cooling channel flow definition at least partially about a core including a ceramic matrix composite material. A metal material is cast about the core and the cooling channel flow definition to form an outer metal shell. In addition, a cooling channel is formed from the cooling channel flow definition in the component.

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: A hard tool configuration (28) and method of manufacturing advanced detailed trailing edge features in a core for casting. The hard tool configuration (28) includes at least a first platform (10) and a second platform (12). The hard tool configuration (28) also includes a first end (22) of a plurality of removable rake elements (14) removably attached to at least one of the first platform (10) and the second platform (12). The hard tool configuration (28) also includes an internal mold geometry (18) in a spacing in between the center facing side (16) of the first platform (10) and the center facing side (16) of the second platform (12).