Abstract: A rare earth-based core for use in the casting of a reactive metal is described. The core contains a ceramic composition which includes at least about 10% by weight of monoclinic rare earth aluminate (RE4Al2O9), wherein RE represents at least one rare earth element; and at least about 10% by weight of at least one free rare earth oxide. The ceramic phase of the composition may include a microstructure which comprises a multitude of substantially spherical pores which are formed as a result of the removal of aluminum metal from the core composition during a heat treatment step. Additional embodiments relate to a method for the fabrication of a ceramic core, employing a rare earth oxide, aluminum metal, and a binder. Methods for removing cores from a cast part are also described.

Abstract: A method of removing an yttria-based core from a niobium-based part is described. In the method, the core is treated with an effective amount of a leaching composition. The leaching composition is based on nitric acid, or a combination of nitric acid and phosphoric acid. The core material is effectively removed from the niobium-based part, and the process of removing the core does not detrimentally affect the quality of the part. Related casting techniques for various niobium-based parts are also described.

Abstract: A method of generating code that permits client access to a business process orchestration running on a server as a web service using the Simple Object Access Protocol (SOAP). Business process orchestrations in XLANG are converted to a web service implementation description from which the Web services code is generated. During runtime, when a SOAP request message comes into the server, it is passed to the target web method. The message is then passed to a Web services adapter that submits the request for further processing by the backend system. The response is forwarded to the Web services adapter, which returns the response as a SOAP response message to the client.

Abstract: A method of fabricating a core for a ceramic shell mold is disclosed. A porous core body is formed from at least about 50% by weight of at least one rare earth metal oxide. The core body is heated under heating conditions sufficient to provide the core with a density of about 35% to about 80% of its theoretical density. The core body is then infiltrated with a liquid colloid or solution of at least one metal oxide compound, e.g., rare earth metal oxides; silica, aluminum oxide, transition metal oxides, and combinations thereof. The infiltrated core body is then heated to sinter the particles without substantially changing the dimensions of the core body. Mold-core assemblies which include such a core body are also described. A description of processes for casting a turbine component, using the core, is also set forth herein.

Abstract: A method of generating code that permits client access to a business process orchestration running on a server as a web service using the Simple Object Access Protocol (SOAP). Business process orchestrations in XLANG are converted to a web service implementation description from which the Web services code is generated. During runtime, when a SOAP request message comes into the server, it is passed to the target web method. The message is then passed to a Web services adapter that submits the request for further processing by the backend system. The response is forwarded to the Web services adapter, which returns the response as a SOAP response message to the client.

Abstract: A blade cover cooling apparatus comprises a blade cover top plate, comprising a plurality of upper ribs, a blade cover bottom plate, comprising a plurality of lower ribs. The blade cover top plate is disposed over the blade cover bottom plate. The upper ribs are disposed at a first angle and the lower ribs are disposed at a second angle with respect to the blade circumferential reference line, respectively to form a plurality of flow redirection areas. The blade cover bottom plate is disposed to pass a coolant from the turbine blade to the blade cover top plate. A fabrication method aligns the blade cover top plate and the blade cover bottom plate to form the plurality of flow redirection areas.

Abstract: An airfoil for an internal combustion engine, such as a gas turbine, formed by use of a preform. The airfoil includes: an outer surface forming the foil shape; and a plurality of craze-free cooling passages extending through the airfoil. In the preferred embodiment, a root on the airfoil joins the airfoil to the hub of a gas turbine vane assembly. Also, in the preferred embodiment, the gas turbine vane assembly is adapted to receive replaceable airfoils.

Abstract: A method of removing substantially all of the volatile component in a green, volatile-containing ceramic article is disclosed. The method comprises freezing the ceramic article; and then subjecting the frozen article to a vacuum for a sufficient time to freeze-dry the article. Frequently, the article is heated while being freeze-dried. Use of this method efficiently reduces the propensity for any warpage of the article. The article is often formed from a ceramic slurry in a gel-casting process. A method for fabricating a ceramic core used in investment casting is also described.

Abstract: The present invention provides a cooling apparatus for cooling a turbine blade. The cooling apparatus comprises a pressure side plate comprising a plurality of pressure ribs, a suction side plate comprising a plurality of suction ribs, and a plurality of flow redirection areas. The pressure side plate is disposed over the suction side plate, where the pressure ribs are disposed at a first angle with respect to a blade span reference line and the suction ribs are disposed at a second angle with respect to the blade span reference line, to form the flow redirection areas. The present invention provides a method of fabricating the cooling apparatus for the turbine blade comprising aligning the pressure side plate and the suction side plate to form the plurality of flow redirection areas between the pressure side plate and the suction side plate.

Abstract: A turbine blade comprises an external pressure side plate comprising a plurality of external pressure ribs, an internal pressure side plate comprising a plurality of internal pressure ribs, and a plurality of pressure flow redirection areas. The external pressure side plate is disposed over the internal pressure side plate to form a pressure side double wall. The external pressure ribs are disposed at a first angle with respect to a blade span reference line and the internal pressure ribs are disposed at a second angle with respect to the blade span reference line to form the pressure flow redirection areas. The pressure side double wall is configured to pass a coolant through the pressure side double wall. A fabrication method aligns the external pressure side plate and the internal pressure side plate to form the pressure flow redirection areas between the external pressure side plate and the internal pressure side plate.

Abstract: The present invention provides a cooling apparatus for cooling a turbine blade. The cooling apparatus comprises a pressure side plate comprising a plurality of pressure ribs, a suction side plate comprising a plurality of suction ribs, and a plurality of flow redirection areas. The pressure side plate is disposed over the suction side plate, where the pressure ribs are disposed at a first angle with respect to a blade span reference line and the suction ribs are disposed at a second angle with respect to the blade span reference line, to form the flow redirection areas. The present invention provides a method of fabricating the cooling apparatus for the turbine blade comprising aligning the pressure side plate and the suction side plate to form the plurality of flow redirection areas between the pressure side plate and the suction side plate.

Abstract: A turbine blade comprises an external pressure side plate comprising a plurality of external pressure ribs, an internal pressure side plate comprising a plurality of internal pressure ribs, and a plurality of pressure flow redirection areas. The external pressure side plate is disposed over the internal pressure side plate to form a pressure side double wall. The external pressure ribs are disposed at a first angle with respect to a blade span reference line and the internal pressure ribs are disposed at a second angle with respect to the blade span reference line to form the pressure flow redirection areas. The pressure side double wall is configured to pass a coolant through the pressure side double wall. A fabrication method aligns the external pressure side plate and the internal pressure side plate to form the pressure flow redirection areas between the external pressure side plate and the internal pressure side plate.

Abstract: A blade cover cooling apparatus comprises a blade cover top plate, comprising a plurality of upper ribs, a blade cover bottom plate, comprising a plurality of lower ribs. The blade cover top plate is disposed over the blade cover bottom plate. The upper ribs are disposed at a first angle and the lower ribs are disposed at a second angle with respect to the blade circumferential reference line, respectively to form a plurality of flow redirection areas. The blade cover bottom plate is disposed to pass a coolant from the turbine blade to the blade cover top plate. A fabrication method aligns the blade cover top plate and the blade cover bottom plate to form the plurality of flow redirection areas.

Abstract: A ceramic casting shell mold having a pre-selected shape comprises alternate, repeating layers of a ceramic coating material and a ceramic stucco, defining a total thickness of the shell mold; and a ceramic-based reinforcing sheet disposed in the alternate, repeating layers of coating material and stucco at an intermediate thickness. The ceramic-based reinforcing sheet comprises a one-piece monolithic, integral body, which comprises a pattern of holes that enhance bonding between the ceramic-based reinforcing sheet and adjacent ones of the alternate, repeating layers of ceramic coating material. The ceramic-based reinforcing sheet conforms to the shape of the mold and providing structural reinforcement to the mold.

Abstract: A method for shielding a molten metal cooling bath used in directional casting of superalloys from a high temperature furnace environment. A plurality of floating ceramic baffles are used, floated on the top of such cooling bath so as to substantially cover the surface thereof. Each baffle member comprises a hollow ceramic member and ceramic seal means sintered to such hollow member so as to form a hermetically sealed chamber within the hollow member. The baffles are displaced during the directional casting process when a mold containing the cast article is lowered into the cooling bath. A ceramic baffle of this construction is also disclosed.

Abstract: A method of removing substantially all of the volatile component in a green, volatile-containing ceramic article is disclosed. The method comprises freezing the ceramic article; and then subjecting the frozen article to a vacuum for a sufficient time to freeze-dry the article. Frequently, the article is heated while being freeze-dried. Use of this method efficiently reduces the propensity for any warpage of the article. The article is often formed from a ceramic slurry in a gel-casting process. A method for fabricating a ceramic core used in investment casting is also described.

Abstract: A ceramic casting shell mold having a pre-selected shape is described. It includes alternate, repeating layers of a ceramic coating material and a ceramic stucco, defining a total thickness of the shell mold; and a ceramic-based mat of reinforcing material disposed in the alternate, repeating layers of coating material and stucco. The reinforcing material for the mat is usually made from a ceramic material, and includes fibers having a bi-directional orientation. A method for making a ceramic casting shell mold is also described, as well as articles cast from such a mold, e.g., superalloy articles.

Abstract: A high temperature insulating composite composition comprising at least one ground silicate mineral and at least one silicone polymer. The at least one ground silicate mineral is at least one mineral selected from the group of olivine group; garnet group; aluminosilicates; ring silicates; chain silicates; and sheet silicates. The high temperature insulating material has particular usefulness for insulating electrical wires.

Abstract: A mold basket, for supporting a mold, for use in a liquid metal bath furnace with an elevator, comprising a flange for suspending the mold basket from the elevator; and a horizontal plate disposed beneath the flange for supporting the mold, wherein the plate is coupled to the flange with a plurality of vertical tie rods.

Abstract: A method of removing substantially all of the volatile component in a green, volatile-containing ceramic article is disclosed. The method comprises freezing the ceramic article; and then subjecting the frozen article to a vacuum for a sufficient time to freeze-dry the article. Frequently, the article is heated while being freeze-dried. Use of this method efficiently reduces the propensity for any warpage of the article. The article is often formed from a ceramic slurry in a gel-casting process. A method for fabricating a ceramic core used in investment casting is also described.