Abstract: A method of working an additively manufactured part includes applying a layer of wax to a part manufactured with an additive manufacturing process. Then a mold is formed over the layer of wax on the part. The wax is then removed from between the mold and the part. The part is then melted in the mold, and then the part is re-solidified in the mold. Finally, the mold is removed.

Abstract: An airfoil according to an exemplary aspect of the present disclosure includes, among other things, an airfoil section having an external wall and an internal wall. The internal wall defines a first reference plane extending in a spanwise direction and through a thickness of the internal wall. A first cavity and a second cavity are separated by the internal wall. A plurality of crossover passages within the internal wall connects the first cavity to the second cavity. The plurality of crossover passages are arranged such that the passage axis of each of the plurality of cooling passages intersects a surface of the second cavity.

Abstract: An airfoil member and platform assembly for a gas turbine engine is provided. The platform to which the airfoil member is anchored is made of a composite material and includes an endwall defining a contoured region for improved aerodynamics. The contoured region influences the flow of gases through the flow passages between the airfoil members, thereby reducing endwall losses due to horseshoe vortexing. The composite material may be woven ceramic matrix composite fibers infiltrated with a ceramic matrix material or woven organic matrix composite fibers infiltrated with an organic matrix material.

Abstract: A method of additive manufacturing comprises determining a first resonant frequency of an unflawed reference workpiece at a first partial stage of completion, fabricating a production workpiece to the first partial stage of completion via additive manufacture, sensing a second resonant frequency of the production workpiece in-situ at the first partial stage of completion, during the fabrication, analyzing the workpiece for flaws based on comparison of the first and second resonant frequencies, and providing an output indicative of production workpiece condition, based on the analysis. An additive manufacturing system comprises an additive manufacturing tool, a sensor, and a controller. The additive manufacturing tool is disposed to construct a workpiece via iterative layer deposition. The sensor is disposed to determine a resonant frequency of the workpiece in-situ at the additive manufacturing tool, during fabrication.

Abstract: A method of working an additively manufactured part includes applying a layer of wax to a part manufactured with an additive manufacturing process. Then a mold is formed over the layer of wax on the part. The wax is then removed from between the mold and the part. The part is then melted in the mold, and then the part is re-solidified in the mold. Finally, the mold is removed.

Abstract: A composite component is disclosed. The composite component may comprise a metal plating deposited on a surface of the composite component, and a metallic feature adhesively bonded to the metal plating. The composite component may further comprise an adhesive layer between the metal plating and the metallic feature. The metal plating may provide a metal-to-metal interface between the surface of the composite component and the metallic feature.

Abstract: A component for a gas turbine engine includes a gas path wall having a first surface, a second surface exposed to hot gas flow, and a cooling hole extending through the gas path wall. The cooling hole includes an inlet formed in the first surface, an outlet formed in the second surface, cooling hole surfaces that define the cooling hole between the inlet and the outlet, and a longitudinal ridge formed along at least one of the cooling hole surfaces. The longitudinal ridge separates the cooling hole into first and second lobes. The cooling hole diverges through the gas path wall, such that cross-sectional area of the cooling hole increases continuously from the inlet through the cooling hole to the outlet.

Abstract: A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified.

Abstract: A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified.

Abstract: A method of manufacturing a replacement body for a component is provided. The method includes the steps of: a) additively manufacturing a crucible for casting of the replacement body; b) solidifying a metal material within the crucible to form a directionally solidified microstructure within the replacement body; and c) removing the crucible to reveal the directionally solidified replacement body.

Abstract: A cooling system for a gas turbine engine comprises a passage capable of receiving cooling air, a compartment radially adjacent thereto and axially aligned therewith, an opening therebetween, a valve within the opening, and a heat exchanger received in the compartment. The valve is moveable between a maximum open position and a minimum open position for increasing or decreasing airflow from the passage into the compartment. At the valve minimum open position, a leakage path is provided between the passage and the compartment, whereby cooling air is capable of passing from the passage to the compartment and toward the heat exchanger at all valve positions. A gas turbine engine is also disclosed.

Abstract: A gas turbine engine component includes an airfoil extending radially from a root section to a tip section and having a trailing edge cooling passageway and first, second and third flow dividers in the cooling passageway. The first, second and third flow dividers have longitudinal axes that are angled based upon a position of the flow divider relative to the tip section of the airfoil.

Abstract: An intermediate component with an internal passageway includes a solid metallic additively manufactured component with an internal passageway in a near finished shape. The component has voids greater than 0 percent but less than approximately 15 percent by volume and up to 15 percent additional material by volume in the near finished shape compared to a desired finished configuration. Also included are a ceramic core disposed within the internal passageway of the component and an outer ceramic shell mold encasing an entirety of the component, such that an entire external surface of the component is covered by the outer ceramic shell mold.

Abstract: A method of working an additively manufactured part includes applying a layer of wax to a part manufactured with an additive manufacturing process. Then a mold is formed over the layer of wax on the part. The wax is then removed from between the mold and the part. The part is then melted in the mold, and then the part is re-solidified in the mold. Finally, the mold is removed.

Abstract: A method of manufacturing a replacement body for a component is provided. The method includes the steps of: a) additively manufacturing a crucible for casting of the replacement body; b) solidifying a metal material within the crucible to form a directionally solidified microstructure within the replacement body; and c) removing the crucible to reveal the directionally solidified replacement body.

Abstract: An intermediate component with an internal passageway includes a solid metallic additively manufactured component with an internal passageway in a near finished shape. The component has voids greater than 0 percent but less than approximately 15 percent by volume and up to 15 percent additional material by volume in the near finished shape compared to a desired finished configuration. Also included are a ceramic core disposed within the internal passageway of the component and an outer ceramic shell mold encasing an entirety of the component, such that an entire external surface of the component is covered by the outer ceramic shell mold.

Abstract: A method of manufacturing a component includes additively manufacturing a crucible; directionally solidifying a metal material within the crucible; and removing the crucible to reveal the component. A component for a gas turbine engine includes a directionally solidified metal material component, the directionally solidified metal material component having been additively manufactured of a metal material concurrently with a core, the metal material having been remelted and directionally solidified.

Abstract: A component for a gas turbine engine including a gas path wall having a first surface and a second surface. A cooling hole extends through the gas path wall from an inlet in the first surface through a transition to an outlet in the second surface. Cusps are formed on the transition.

Abstract: A method of manufacturing a fuel component for a gas turbine engine combustor includes additive manufacturing a sacrificial core and manufacturing a fuel component body at least partially around the sacrificial core. The sacrificial core is at least partially removed to at least partially define an internal geometry of the fuel component. An additively manufactured sacrificial core for a fuel component of a gas turbine engine combustor includes a first structure and a second structure. The first structure at least partially defines a first passage of the fuel component. The second structure at least partially defines a second passage of the fuel component. The second structure at least partially surrounds the first structure.

Abstract: A gas turbine engine component includes a wall having first and second wall surfaces, a cooling hole extending through the wall and a convexity. The cooling hole includes an inlet located at the first wall surface, an outlet located at the second wall surface, a metering section extending downstream from the inlet and a diffusing section extending from the metering section to the outlet. The diffusing section includes a first lobe diverging longitudinally and laterally from the metering section and a second lobe adjacent the first lobe and diverging longitudinally and laterally from the metering section. The convexity is located near the outlet.