Abstract: A method of forming a turbine blade or vane is provided and includes forming a wax pattern in a turbine blade or vane shape and additively forming a positive witness band around a tip portion of the wax pattern.

Abstract: A component (34A, 34B, 34C) has a core formed of a stack (25, 36) of sheets (20) of material with cutouts (22A) aligned to form passages (38) in the core. An outer casing (29) spans the stack axially (51), brackets at least parts of opposed ends of the stack, and holds the sheets together in axial compression (46). Respective cooperating elements (30, 31) on the casing and the stack may register the casing with respect to the stack. Pins (24) in some sheets may engage holes (23) in adjacent sheets to register the sheets with each other. The casing may be segmented (28A, 28B, 28C). A hoop (66) may be compressed around the segmented casing. A gas turbine fuel injector may be formed of a stack (36) with an inlet element (44) compressed (46) onto the stack by the casing (29).

Abstract: A component (34A, 34B, 34C) has a core formed of a stack (25, 36) of sheets (20) of material with cutouts (22A) aligned to form passages (38) in the core. An outer casing (29) spans the stack axially (51), brackets at least parts of opposed ends of the stack, and holds the sheets together in axial compression (46). Respective cooperating elements (30, 31) on the casing and the stack may register the casing with respect to the stack. Pins (24) in some sheets may engage holes (23) in adjacent sheets to register the sheets with each other. The casing may be segmented (28A, 28B, 28C). A hoop (66) may be compressed around the segmented casing. A gas turbine fuel injector may be formed of a stack (36) with an inlet element (44) compressed (46) onto the stack by the casing (29).

Abstract: A ceramic casting vessel (92) including an insert (94) extending between a shell (91) and a core (93) of the vessel to define a cooling channel of an alloy component cast therein. The insert may include a portion (96) running generally parallel to a surface of the shell to define a cooling channel running generally parallel to a surface of the component. Ends of the insert may be disposed in respective grooves (95, 97) formed in the shell and/or core.

Abstract: A method of manufacturing a component, including providing a three-dimensional computer model of the component to be produced; deconstructing the three-dimensional computer model by defining a plurality of model slices; forming a plurality of metallic foils, where each foil corresponds to a specific model slice; assembling the plurality of formed foils in a tool to form a three-dimensional component stack; and bonding the three-dimensional component stack to form the component. Characteristics of the foils may differ in various portions of the stack, such as being a different material, having a different thickness, or having a different grain orientation. The control of dimensional tolerances of internal structures, such as cooling passages, in three dimensions is devolved into two separate steps of 1) selecting a thickness of each slice/foil, and 2) controlling in two dimensions a material removal process applied to the respective foil.

Abstract: A hollow turbine engine component with complex internal features can include a first region and a second, high resolution region. The first region can be defined by a first ceramic core piece formed by any conventional process, such as by injection molding or transfer molding. The second region can be defined by a second ceramic core piece formed separately by a method effective to produce high resolution features, such as tomolithographic molding. The first core piece and the second core piece can be joined by interlocking engagement that once subjected to an intermediate thermal heat treatment process thermally deform to form a three dimensional interlocking joint between the first and second core pieces by allowing thermal creep to irreversibly interlock the first and second core pieces together such that the joint becomes physically locked together providing joint stability through thermal processing.

Abstract: An investment casting process wherein the wax pattern tool (42) is flexible to provide compliant support for an enclosed ceramic core (10) and to facilitate removal of the tool from the cast wax pattern (52) even when the cast shape would otherwise require multiple pull planes. Positioning pins (106) may extend from the flexible tool to make compliant contact against the core during the wax injection step. The pins may cooperate with a pedestal (128) formed on the core to support the core along multiple axes during wax injection, thereby allowing a higher wax injection pressure without damage to the core.

Abstract: A turbine engine component, such as a turbine blade or vane, with complex internal features can be cast using a core having a first region with normal resolution features and a second region with high resolution features. The core can be formed from a single structure. Alternatively, the first region can be defined by a first ceramic core piece, which can be formed by any conventional process, such as by injection molding or transfer molding. The second region can be defined by a second ceramic core piece formed separately by a method effective to produce high resolution features, such as tomo lithographic molding. The first core piece and the second core piece can be joined by interlocking engagement, such as by male and female dovetails. The high resolution features can be effective to produce high efficiency internal cooling features in the cast component.

Abstract: A weightlifting belt with hook for a person exercising to be able to hang a weight from a belt around their waist. This invention enables the quick and easy removal (or addition) of the weight by the person exercising or by a third party (‘spotter’) while the person exercising remains in the exercising position on the exercise equipment. The weight hanging from the belt increases their total weight and therefore the difficulty of the exercise and in turn the exercise's effectiveness. The ‘pull-up’, ‘chin-up’ and ‘dip’ exercises are particularly targeted with this invention. The inventive device includes a belt that goes around a person's waist with a hook attached to hang a dumbbell-style weight from. A metal plate formed to create a hook from which to hang a dumbbell-style weight. A belt is passed through a slot-shaped hole in the metal plate so that a person can wear the device around their waist.