Abstract: An air-cooled turbine blade is provided having an airfoil shape defined by a convex suction side wall, a concave pressure side wall, a leading edge, a trailing edge, a root and a tip, the walls and the tip each including an interior surface that defines an interior with the root, the trailing edge including a plurality of slots formed thereon. The blade includes a suction side flow circuit formed therein comprising a forward and an aft flow circuit. The blade also includes a tip flow circuit extending along the tip interior surface to at least one of the trailing edge slots and including a first and a second opening, the first opening in flow communication with the suction side forward flow circuit outlet, and the second opening in flow communication with a cross-over hole of the suction side aft flow circuit. Methods of manufacturing the blade are also provided.

Abstract: A core assembly including two cores is used to manufacture a blade. The first core has an outer surface shaped to complement the tip wall bottom surface. The second core has a tip surface, a side surface, and a protrusion or a depression. The tip surface is shaped to complement at least a portion of the tip wall top surface and is configured to be disposed proximate the first core. The side surface is shaped to complement at least a portion of the side wall, and the protrusion extends from the second core side surface to contact at least a portion of the ceramic mold inner surface. In embodiments employing a depression, the depression is formed in the side surface.

Abstract: Methods are provided for modifying an airfoil internal cooling circuit that include a flow path configured to direct air through the airfoil in a direction and the airfoil having a leading edge, a trailing edge, and a first and a second wall therebetween, each wall having an inner and an outer surface, the inner surfaces defining a cavity and having features forming at least a portion of the internal cooling circuit. The methods may include the steps of forming a pilot hole through the airfoil first and second walls at a predetermined location, forming an insert hole based on the predetermined location, the insert hole enveloping the pilot hole and configured to receive at least a portion of an insert configured to modify the internal cooling circuit flow path, placing the insert into the insert hole, and bonding the insert to the airfoil first and second walls.

Abstract: A core assembly including two cores is used to manufacture a blade. The first core has an outer surface shaped to complement the tip wall bottom surface. The second core has a tip surface, a side surface, and a protrusion or a depression. The tip surface is shaped to complement at least a portion of the tip wall top surface and is configured to be disposed proximate the first core. The side surface is shaped to complement at least a portion of the side wall, and the protrusion extends from the second core side surface to contact at least a portion of the ceramic mold inner surface. In embodiments employing a depression, the depression is formed in the side surface.

Abstract: An air-cooled turbine blade is provided having an airfoil shape defined by a convex suction side wall, a concave pressure side wall, a leading edge, a trailing edge, a root and a tip, the walls and the tip each including an interior surface that defines an interior with the root, the trailing edge including a plurality of slots formed thereon. The blade includes a suction side flow circuit formed therein comprising a forward and an aft flow circuit. The blade also includes a tip flow circuit extending along the tip interior surface to at least one of the trailing edge slots and including a first and a second opening, the first opening in flow communication with the suction side forward flow circuit outlet, and the second opening in flow communication with a cross-over hole of the suction side aft flow circuit. Methods of manufacturing the blade are also provided.

Abstract: A compressor scroll housing for use in conjunction with turbo-machinery, particularly applicable in aircraft. The scroll housing can include a plurality of scroll vanes arrayed around the scroll housing. Scroll vanes, integrally formed with the scroll housing, carry stress load on the scroll housing, including the load from fluid pressure within the scroll and carcass loading from the engine. The plurality of scroll vanes adapted for guiding flow of fluid from an inlet to an outlet while supporting the scroll housing. Chord length and cross sectional area of each scroll vane can be sized to maintain an equal stress in all scroll vanes. A method of making the scroll housing for use with an impeller connected to an engine is disclosed, as well as a method of operating turbo-machinery including supporting a load on the scroll housing with scroll vanes while maintaining an equal stress on each scroll vane.

Abstract: A turbine engine compressor design utilizing multiple component integration, thereby reducing the number of required engine components. In conventional compressor designs, a multiple component system makes it difficult to predict the structural behaviors due to thermal and mechanical loading during transient conditions. The compressor design of the present invention has three main parts: a forward bearing housing, a bell-mouth (heat shield) and a coupled impeller shroud/diffuser. Such a design achieves the design objectives of the present invention, including reducing weight, reducing cost, minimizing tolerance build up and improving aerodynamic performance by utilizing multiple component integration for multiple modes of engine operation.