Abstract: A blade (100) has an airfoil (106) having a leading edge (114), a trailing edge (116), a pressure side (118), and a suction side (120) and extending from an inboard end (110) to a tip (112). An attachment root (108) is at the inboard end. The blade comprises an aluminum alloy substrate (102) and a coating at the tip (130). The coating (130) comprises an anodic layer (160) atop the substrate and an aluminum oxide layer (162) atop the anodic layer.

Abstract: A blade (100) has an airfoil (106) having a leading edge (114), a trailing edge (116), a pressure side (118), and a suction side (120) and extending from an inboard end (110) to a tip (112). An attachment root (108) is at the inboard end. The blade comprises an aluminum alloy substrate (102) and a coating at the tip (130). The coating (130) comprises an anodic layer (160) atop the substrate and an aluminum oxide layer (162) atop the anodic layer.

Abstract: Removing of a casting core from a metal casting leaves at least one opening in a surface of the metal. The opening is filled with a sacrificial material. The metal and sacrificial material are machined at the opening. After the machining, a remainder of the sacrificial material is removed.

Abstract: A protective coating for a surface exposed to hot gas flow comprises a thermal layer, a conducting layer and an abrasive layer. The thermal layer comprises stabilized zirconia, and overlies the surface. The conducting layer overlies the thermal layer. The abrasive layer comprises abrasive particles bonded in a metal matrix that is electroplated onto the conducting layer.

Abstract: Removing of a casting core from a metal casting leaves at least one opening in a surface of the metal. The opening is filled with a sacrificial material. The metal and sacrificial material are machined at the opening. After the machining, a remainder of the sacrificial material is removed.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.

Abstract: To destructively remove a casting core from a cast part, the part is exposed to a combination of nitric acid and sulfuric acid. The combination may have, by volume, a nitric acid concentration of 4-20 times the sulfuric acid concentration. The combination may be an aqueous solution including, by volume, 40-60% nitric acid and 3-10% sulfuric acid. The method may remove a ceramic casting core and a refractory metal-based casting core. A first leaching step may remove a major portion of the ceramic casting core and may comprise alkaline leaching. A second leaching step may remove a major portion of the refractory metal-based casting core and may comprise acid leaching. The acid leaching may comprise the combination of nitric acid and sulfuric acid.

Abstract: A core for investment casting processes includes a core having one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

Abstract: A protective coating for a surface exposed to hot gas flow comprises a thermal layer, a conducting layer and an abrasive layer. The thermal layer comprises stabilized zirconia, and overlies the surface. The conducting layer overlies the thermal layer. The abrasive layer comprises abrasive particles bonded in a metal matrix that is electroplated onto the conducting layer.

Abstract: A process for reducing secondary reaction zone formation articles includes the steps of non-selective removing an external surface of an as-cast article free of coating to form an as-cast article having a surface substantially free of residual surface stress; and applying a coating material upon the surface substantially free of residual surface stress to form a coated as-cast article having a coating layer disposed upon the surface substantially free of residual surface stress.

Abstract: A core for investment casting processes includes a core having one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

Abstract: A core for investment casting processes includes a core comprising one or more ceramic materials; and an exterior layer of metal material not susceptible to oxidation under investment casting operating conditions. A method for casting a turbine engine component having an internal passageway includes the steps of forming one or more mold sections each having internal surfaces and at least one of the aforementioned cores for forming one or more turbine engine components having at least one internal passageway; assembling the one or more mold sections; introducing a molten alloy into the one or more assembled mold sections; and consuming the metal of the at least one core during the process.

Abstract: A process for repairing components includes the steps of providing a component having an affected area on a surface of a component to be repaired; depositing a repair material over the affected area on the surface of the component so that the repair material plastically deforms without melting and bonds to the affected area upon impact with the affected area and thereby covers the affected area; providing a sulfuric acid based anodizing solution; anodizing a deposited repair material on the surface of said component in the sulfuric acid based anodizing solution; consuming only a portion of the deposited repair material to form a hard anodized coating layer upon the deposited repair material to form a hard anodized coated component; providing a corrosion resistant sealant solution; and contacting a hard anodized coated component with the corrosion resistant sealant solution to form a corrosion resistant sealant coating on the hard anodized coated component.

Abstract: A substrate is coated by applying a first layer atop the substrate and including, in major weight part, a non-refractory first metal. A second layer is applied atop the first layer and includes, in major weight part, a carbide and/or nitride of a second metal. A third layer is applied atop the second layer and comprises, in major weight part, a ceramic. The substrate may be a refractory metal-based investment casting core.

Abstract: Removing of a casting core from a metal casting leaves at least one opening in a surface of the metal. The opening is filled with a sacrificial material. The metal and sacrificial material are machined at the opening. After the machining, a remainder of the sacrificial material is removed.

Abstract: A method for forming an investment casting core comprises cutting a patterned core precursor from refractory metal-based sheet. The cutting forms recast along the cuts. An oxide is grown on non-recast areas. The recast is substantially chemically removed but substantially leaving the oxide. The core precursor may then be shaped.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.

Abstract: To destructively remove a refractory metal casting core from a cast part the part is exposed to a combination of nitric acid and sulfuric acid.

Abstract: A substrate is coated by applying a first layer atop the substrate and comprising, in major weight part, a non-refractory first metal. A second layer is applied atop the first layer and comprises, in major weight part, a carbide and/or nitride of a second metal. A third layer is applied atop the second layer and comprises, in major weight part, a ceramic. The substrate may be a refractory metal-based investment casting core.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.