Abstract: An investment casting process for manufacturing a cast component is provided. The investment casting process includes forming a core, casting the cast component about the core such that a core positioning feature provides a location of an anticipated pilot hole in the cast component, removing the core from the cast component once the casting is completed, locating, forming and sizing a pilot hole to form a resized pilot hole that can receive a sealing plug and installing the sealing plug into the resized pilot hole.

Abstract: An investment casting process for manufacturing a cast component is provided. The investment casting process includes forming a core, casting the cast component about the core such that a core positioning feature provides a location of an anticipated pilot hole in the cast component, removing the core from the cast component once the casting is completed, locating, forming and sizing a pilot hole to form a resized pilot hole that can receive a sealing plug and installing the sealing plug into the resized pilot hole.

Abstract: A method for casting a blade, the blade with an airfoil having: a tip having at least one of a tip pocket and a tip shelf. Each said at least one of a tip pocket and a tip shelf having a base surface and a sidewall surface. The method includes forming a shell, the forming of the shell including shelling a pattern having at least one ceramic casting core; and casting in the shell, the shell having a first portion formed by the at least one ceramic casting core and a second potion formed by applied shell material. For at least a first tip pocket or tip shelf of the least one of a tip pocket and a tip shelf, the at least one ceramic casting core molds the base surface and the sidewall surface and an adjacent portion of at least one of the pressure side and the suction side spanwise inboard of the base surface.

Abstract: An investment casting process for manufacturing a cast component is provided. The investment casting process includes forming a core, casting the cast component about the core such that a core positioning feature provides a location of an anticipated pilot hole in the cast component, removing the core from the cast component once the casting is completed, locating, forming and sizing a pilot hole to form a resized pilot hole that can receive a sealing plug and installing the sealing plug into the resized pilot hole.

Abstract: An investment casting process for manufacturing a cast component is provided. The investment casting process includes forming a core, casting the cast component about the core such that a core positioning feature provides a location of an anticipated pilot hole in the cast component, removing the core from the cast component once the casting is completed, locating, forming and sizing a pilot hole to form a resized pilot hole that can receive a sealing plug and installing the sealing plug into the resized pilot hole.

Abstract: A method for casting a blade, the blade with an airfoil having: a tip having at least one of a tip pocket and a tip shelf. Each said at least one of a tip pocket and a tip shelf having a base surface and a sidewall surface. The method includes forming a shell, the forming of the shell including shelling a pattern having at least one ceramic casting core; and casting in the shell, the shell having a first portion formed by the at least one ceramic casting core and a second potion formed by applied shell material. For at least a first tip pocket or tip shelf of the least one of a tip pocket and a tip shelf, the at least one ceramic casting core molds the base surface and the sidewall surface and an adjacent portion of at least one of the pressure side and the suction side spanwise inboard of the base surface.

Abstract: A die setting apparatus for a ceramic core is provided. The die setting apparatus includes a first setter abuttable with a first side of the ceramic core and a second setter abuttable with a second side of the ceramic core opposite the first side. At least one of the first and second setters includes two or more pieces respectively arranged to form one or more gaps. Each of the one or more gaps is oriented to thermally adjust in correspondence with thermal changes of the ceramic core during a firing process thereof.

Abstract: A die setting apparatus is provided for a ceramic core is provided. The die setting apparatus includes a first setter abuttable with a first side of the ceramic core and a second setter abuttable with a second side of the ceramic core opposite the first side. At least one of the first and second setters includes two or more pieces respectively arranged to form one or more gaps. Each of the one or more gaps is oriented to thermally adjust in correspondence with thermal changes of the ceramic core during a firing process thereof.

Abstract: A cast work piece includes a cast metal component section and a sprue section connected to the cast metal component section. The cast metal component section and a portion of the sprue section have a first grain orientation and another portion of the sprue section has a second grain orientation such that there is a microstructural discontinuity where the first grain orientation meets the second grain orientation in the sprue section.

Abstract: A cast work piece includes a cast metal component section and a sprue section connected to the cast metal component section. The cast metal component section and a portion of the sprue section have a first grain orientation and another portion of the sprue section has a second grain orientation such that there is a microstructural discontinuity where the first grain orientation meets the second grain orientation in the sprue section.