Abstract: A method of manufacturing a turbine blade includes (a) supporting a turbine blade internal core support at opposite ends such that radially inner and outer ends of the turbine blade remain open during casting; (b) casting the blade including the airfoil portion, wherein the radially outer edge of the airfoil portion is inclined relative to horizontal; (c) machining the radially outer edge of the airfoil portion to form a peripheral shoulder about a radially outer opening in the airfoil portion; and (d) seating a tip cap on the peripheral shoulder and fixing the tip cap to the airfoil portion of the blade.

Abstract: A turbine bucket includes a cooling circuit through a dovetail section, a shank section and an airfoil section. The cooling circuit is configured to maximize cooling ability and maximize a useful life at base load operation at firing temperatures of up to 2084° F. while minimizing negative effects on performance. The cooling circuit includes a plurality of cooling holes having predetermined positions and sizes, resulting in increased cooling flow near a trailing edge of the airfoil section and effecting turbulation in the airfoil section to increase bulk and local creep margins throughout the airfoil section.