Abstract: A method of forming a component includes the steps of placing a core into a mold and pouring a component material around the core. The component material is allowed to solidify. The core is then removed from within the material, leaving a component having at least a first and a second cavity formed by the core. A first filler material is moved into the first cavity, and a second filler material is moved into the second cavity. The component is inspected for the presence of an apparent residual core within the first cavity and the second cavity. The location is identified of the apparent residual core from the core based upon an identification of whether the location of the apparent residual core is in the first or second filler materials. A method of inspecting a component formed by investment casting is also disclosed.

Abstract: An example die casting system includes a die comprised of a plurality of die components that define a die cavity configured to receive a molten metal. One of the die components comprises a material that is not reactive with the molten metal and has a melting temperature above 815 degrees Celsius. The die casting system may be used in a method for die casting a gas turbine engine component.

Abstract: Methods are provided for manufacturing a component. In one method, first metal material is cast into a first body. At least a portion of the first body is machined. Second metal material is cast onto at least the machined portion of the first body to form a monolithic second body. A first portion of the second body is formed by the first metal material, A second portion of the second body is formed by the second metal material. The second metal material is different from the first metal material.

Abstract: A method for evaluating a turbine component includes inducing a thermal response of the component at an initial time, capturing a two-dimensional infrared image of the thermal response of the component with a thermal imaging device, wherein the two-dimensional infrared image comprises a plurality of infrared image pixels, generating a two-dimension to three-dimension mapping template to correlate two-dimensional infrared image data with three-dimensional locations on the component, mapping at least a subset of the plurality of infrared image pixels of the two-dimensional infrared image to three-dimensional coordinates using the mapping template, and generating a three-dimensional infrared image and infrared data of the component from the mapped infrared image pixels to three-dimensional coordinates, wherein the three-dimensional infrared image and infrared data is used to qualify the component for use.

Abstract: A method of manufacturing a core for casting a component can include manufacturing a core for at least partially forming an internal passage architecture of a component with a material including radiopaque particles. A method can include removing a material including radio opaque particles from an internal passage architecture of a component; and inspecting the component via radiographic imaging at gamma/X-ray wavelengths to detect residual material. A core for use in casting an internal passage architecture of a component can include a material with radiopaque particles dispersed therein.

Abstract: A method of forming a component includes the steps of placing a core into a mold and pouring a component material around the core. The component material is allowed to solidify. The core is then removed from within the material, leaving a component having at least a first and a second cavity formed by the core. A first filler material is moved into the first cavity, and a second filler material is moved into the second cavity. The component is inspected for the presence of an apparent residual core within the first cavity and the second cavity. The location is identified of the apparent residual core from the core based upon an identification of whether the location of the apparent residual core is in the first or second filler materials. A method of inspecting a component formed by investment casting is also disclosed.

Abstract: A method for evaluating a turbine component includes inducing a thermal response of the component at an initial time, capturing a two-dimensional infrared image of the thermal response of the component with a thermal imaging device, wherein the two-dimensional infrared image comprises a plurality of infrared image pixels, generating a two-dimension to three-dimension mapping template to correlate two-dimensional infrared image data with three-dimensional locations on the component, mapping at least a subset of the plurality of infrared image pixels of the two-dimensional infrared image to three-dimensional coordinates using the mapping template, and generating a three-dimensional infrared image and infrared data of the component from the mapped infrared image pixels to three-dimensional coordinates, wherein the three-dimensional infrared image and infrared data is used to qualify the component for use.

Abstract: An investment casting system includes a core having at least one fine detail, a shell positioned relative to said core, and a strengthening coating applied at least to the at least one fine detail.

Abstract: A hollow metal article can be fabricated by casting a molten metal alloy around a core, solidifying the molten metal alloy to form a metal article, and chemically removing the core from the metal article to form a hollow cavity in the metal article. The core includes a ceramic core body and an x-ray radiopaque coating disposed on the ceramic core body. A method for testing the hollow metal article includes submitting the hollow metal article to x-ray imaging and determining based upon the x-ray imaging whether any of the x-ray radiopaque coating of the core remains in the hollow metal article.

Abstract: Methods are provided for manufacturing a component. In one method, first material is cast into a first body. At least a portion of the first body is machined. Second metal material is cast onto at least the machined portion of the first body to form a monolithic second body. A first portion of the second body is formed by the first metal material. A second portion of the second body is formed by the second metal material. The second metal material is different from the first metal material.

Abstract: A method of manufacturing a core for casting a component can include manufacturing a core for at least partially forming an internal passage architecture of a component with a material including radiopaque particles. A method can include removing a material including radio opaque particles from an internal passage architecture of a component; and inspecting the component via radiographic imaging at gamma/X-ray wavelengths to detect residual material. A core for use in casting an internal passage architecture of a component can include a material with radiopaque particles dispersed therein.

Abstract: A method of remanufacturing a component including at least partially filling an internal passage architecture of a component with a salt-based protective fill; filling at least one of a multiple of cooling holes of the internal passage architecture subsequent to the at least partially filling the internal passage architecture of the component with the salt-based protective fill; and removing the salt-based protective fill subsequent to filling at least one of the multiple of cooling holes.

Abstract: A metal casting apparatus includes a feeder for providing a molten metallic material. A mold includes a sprue and a component cavity. The sprue is arranged to receive the molten metallic material from the feeder and the component cavity is arranged to receive the molten metallic material from the sprue. A starter is arranged adjacent the component cavity and is operable to induce a first grain orientation upon solidification of the molten metallic material. The sprue includes an aborter that is arranged to induce a second grain orientation upon solidification of the molten metallic material.

Abstract: A metal single crystal turbine component with internal passageways includes a polycrystalline turbine blade formed by additive manufacturing. The turbine component is remelted and directionally solidified to form the single crystal turbine component with internal passageways.

Abstract: An intermediate component with an internal passageway includes a solid metallic additively manufactured component with an internal passageway in a near finished shape. The component has voids greater than 0 percent but less than approximately 15 percent by volume and up to 15 percent additional material by volume in the near finished shape compared to a desired finished configuration. Also included are a ceramic core disposed within the internal passageway of the component and an outer ceramic shell mold encasing an entirety of the component, such that an entire external surface of the component is covered by the outer ceramic shell mold.

Abstract: A die casting and a method for die casting a metal having a melting temperature of at least 1500° F. (815° C.) are disclosed. A molten volume of metal is injected to a casting die which includes a main cavity corresponding to an as-cast structure, a first reservoir, and a first runner arrangement. The first runner arrangement is configured to fluidly communicate molten metal between the first reservoir and the main cavity. After the injecting step, the casting die is sealed. The injected molten volume of metal is equiaxially solidified generally from a first portion of the main cavity distal to the first reservoir toward a second portion of the main cavity proximal to the first reservoir. During the equiaxial solidifying step, the main cavity is backfilled with at least a portion of the injected molten volume via the first runner arrangement.

Abstract: An intermediate component with an internal passageway includes a solid metallic additively manufactured component with an internal passageway in a near finished shape. The component has voids greater than 0 percent but less than approximately 15 percent by volume and up to 15 percent additional material by volume in the near finished shape compared to a desired finished configuration. Also included are a ceramic core disposed within the internal passageway of the component and an outer ceramic shell mold encasing an entirety of the component, such that an entire external surface of the component is covered by the outer ceramic shell mold.

Abstract: A method of forming a metal single crystal turbine component with internal passageways includes forming a polycrystalline turbine blade with internal passageways by additive manufacturing and filling the passageways with a core ceramic slurry. The ceramic slurry is then treated to harden the core and the turbine component is encased in a ceramic shell which is treated to form a ceramic mold. The turbine component in the mold is then melted and directionally solidified in the form of a single crystal. The outer shell and inner ceramic core are then removed to form a finished single crystal turbine component with internal passageways.

Abstract: One embodiment includes a method to regenerate a component (10). The method includes additively manufacturing a component (10) to have voids greater than 0 percent but less than approximately 15 percent in a near finished shape. The component (10) is encased in a shell mold (22). The shell mold (22) is cured. The encased component (10) is placed in a furnace and the component (10) is melted. The component (10) is solidified in the shell mold (22). The shell mold (22) is removed from the solidified component (10).

Abstract: One embodiment includes a method to regenerate a component. The method includes additively manufacturing the component with at least a portion of the component in a near finished shape. The component is encased in a shell mold, the shell mold is cured, the encased component is placed in a furnace and the component is melted, the component is solidified in the shell mold, and the shell mold is removed from the solidified component.