Abstract: An airfoil for a gas turbine engine in which the airfoil includes an internal cooling system formed from one or more midchord cooling channels with a corrugated insert positioned therein and creating nearwall leading edge, pressure side and suction side nearwall cooling channels.

Abstract: An investment casting method for a cast ceramic core (110), including an airfoil portion (116) shaped to define an inner surface (56) of an airfoil (52) of a vane segment (50) and an integral shell portion (122) having a backside-shaping surface (120) shaped to define a backside surface (68) of a shroud (62) of the vane segment. The backside-shaping surface has a higher elevation (132) and a lower elevation (134). The higher elevation is set apart from a nearest point (138) on the airfoil portion by the lower elevation. The airfoil portion and the shell portion are cast as a monolithic body during a single casting pour.

Abstract: An investment casting method for a cast ceramic core (110), including an airfoil portion (116) shaped to define an inner surface (56) of an airfoil (52) of a vane segment (50) and an integral shell portion (122) having a backside-shaping surface (120) shaped to define a backside surface (68) of a shroud (62) of the vane segment. The backside-shaping surface has a higher elevation (132) and a lower elevation (134). The higher elevation is set apart from a nearest point (138) on the airfoil portion by the lower elevation. The airfoil portion and the shell portion are cast as a monolithic body during a single casting pour.

Abstract: A cast ceramic core (110), including: an airfoil portion (116) shaped to define an inner surface (56) of an airfoil (52) of a vane segment (50); and a shell portion (122) having a backside-shaping surface (120) shaped to define a backside surface (68) of a shroud (62) of the vane segment. The backside-shaping surface has a higher elevation (132) and a lower elevation (134). The higher elevation is set apart from a nearest point (138) on the airfoil portion by the lower elevation. The airfoil portion and the shell portion are cast as a monolithic body during a single casting pour.

Abstract: A component wall in a turbine engine. The component wall includes a substrate, a trench, and a plurality of cooling passages. The substrate has a first surface and a second surface opposed from the first surface. The trench is located in the second surface and is defined by a bottom surface between the first and second surfaces, a first sidewall, and a second sidewall spaced from the first sidewall. The first sidewall extends radially outwardly continuously from the bottom surface of the trench to the second surface. The first sidewall includes a plurality of first protuberances extending toward the second sidewall. The cooling passages extend through the substrate from the first surface to the bottom surface of the trench. Outlets of the cooling passages are arranged within the trench such that cooling air exiting the cooling passages is directed toward respective ones of the first protuberances.

Abstract: A film cooling structure formed in a component wall of a turbine engine and a method of making the film cooling structure. The film cooling structure includes a plurality of individual diffusion sections formed in the wall, each diffusions section including a single cooling passage for directing cooling air toward a protuberance of a wall defining the diffusion section. The film cooling structure may be formed with a masking template including apertures defining shapes of a plurality of to-be-formed diffusion sections in the wall. A masking material can be applied to the wall into the apertures in the masking template so as to block outlets of cooling passages exposed through the apertures. The masking template can be removed and a material may be applied on the outer surface of the wall such that the material defines the diffusion sections once the masking material is removed.

Abstract: A component wall in a turbine engine. The component wall includes a substrate, a trench, and a plurality of cooling passages. The substrate has a first surface and a second surface opposed from the first surface. The trench is located in the second surface and is defined by a bottom surface between the first and second surfaces, a first sidewall, and a second sidewall spaced from the first sidewall. The first sidewall extends radially outwardly continuously from the bottom surface of the trench to the second surface. The first sidewall includes a plurality of first protuberances extending toward the second sidewall. The cooling passages extend through the substrate from the first surface to the bottom surface of the trench. Outlets of the cooling passages are arranged within the trench such that cooling air exiting the cooling passages is directed toward respective ones of the first protuberances.

Abstract: A component in a gas turbine engine includes an airfoil extending radially outwardly from a platform associated with the airfoil. The airfoil includes opposed pressure and suction sidewalls, which converge at a first location defined at a leading edge of the airfoil and at a second location defined at a trailing edge of the airfoil opposed from the leading edge. The component includes a built-up surface adjacent to the leading edge at an intersection between the pressure sidewall and the platform, and at least one cooling passage at least partially within the built-up surface at the intersection between the pressure sidewall and the platform. The at least one cooling passage is in fluid communication with a main cooling channel within the airfoil and has an outlet at the platform for providing cooling fluid directly from the main cooling channel to the platform.

Abstract: A built-up gas turbine component is prepared by providing a gas turbine component having a component surface and being made of a component base metal having a component base metal composition. A buildup tape is supplied having a net metallic buildup composition different from the component base metal composition. The buildup tape includes a first metallic constituent having a first melting point, and a second metallic constituent having a second melting point. The first metallic constituent and second metallic constituent together have the net metallic buildup composition. A nonmetallic binder binds together the first metallic constituent and the second metallic constituent. The buildup tape is applied to the component surface and heated to a brazing temperature greater than the first melting point and less than the second melting point.

Abstract: A built-up gas turbine component is prepared by providing a gas turbine component having a component surface and being made of a component base metal having a component base metal composition. A buildup tape is supplied having a net metallic buildup composition different from the component base metal composition. The buildup tape includes a first metallic constituent having a first melting point, and a second metallic constituent having a second melting point. The first metallic constituent and second metallic constituent together have the net metallic buildup composition. A nonmetallic binder binds together the first metallic constituent and the second metallic constituent. The buildup tape is applied to the component surface and heated to a brazing temperature greater than the first melting point and less than the second melting point.