Abstract: A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Abstract: A refractory metal core for use in a casting system has a coating for providing oxidation resistance during shell fire and protection against reaction/dissolution during casting. In a first embodiment, the coating includes at least one oxide and a silicon containing material. In a second embodiment, the coating includes an oxide selected from the group of calcia, magnesia, alumina, zirconia, chromia, yttria, silica, hafnia, and mixtures thereof. In a third embodiment, the coating includes a nitride selected from the group of silicon nitride, sialon, titanium nitride, and mixtures thereof. Other coating embodiments are described in the disclosure.

Abstract: A composite core for an investment casting process, the core including both a ceramic portion and a refractory metal portion, with the refractory metal portion being so disposed as to perform the function of a plurality of such refractory metal elements. In particular, a refractory metal element attached to a trailing edge of a ceramic element extends beyond the plane of a tip end of the ceramic element so as to replace the refractory metal element otherwise extending from the ceramic tip edge. The refractory metal element also extends beyond the space to be occupied by the wax casting, both in the direction of the tip end and the trailing edge such that improved placement and securing of the core is facilitated during the casting process. A further embodiment uses a single refractory metal element that extends into both the airfoil portion and an orthogonal extending platform portion thereof.

Abstract: A composite core for an investment casting process, the core being comprised of both a ceramic portion and a refractory metal portion, with the refractory metal portion being so disposed as to perform the function of a plurality of such refractory metal elements. In particular, a refractory metal element attached to a trailing edge of a ceramic element extends beyond the plane of a tip end of the ceramic element so as to replace the refractory metal element otherwise extending from the ceramic tip edge. The refractory metal element also extends beyond the space to be occupied by the wax casting, both in the direction of the tip end and the trailing edge such that improved placement and securing of the core is facilitated during the casting process. A further embodiment uses a single refractory metal element that extends into both the airfoil portion and an orthogonal extending platform portion thereof.

Abstract: A casting system for forming a gas turbine engine component is provided. The casting system, in a first embodiment, comprises a shaped refractory metal sheet having a plurality of features for forming a plurality of film cooling passages, which features are formed from refractory metal material bent out of the sheet. The casting system for forming a gas turbine engine component in a second embodiment comprises a metal wall having an airfoil shape and a refractory metal core adjacent the metal wall and having a shape corresponding to the shape of the metal wall.

Abstract: A casting system for forming a gas turbine engine component is provided. The casting system, in a first embodiment, comprises a shaped refractory metal sheet having a plurality of features for forming a plurality of film cooling passages, which features are formed from refractory metal material bent out of the sheet. The casting system for forming a gas turbine engine component in a second embodiment comprises a metal wall having an airfoil shape and a refractory metal core adjacent the metal wall and having a shape corresponding to the shape of the metal wall.