Abstract: The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Abstract: The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Abstract: The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.

Abstract: Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone including a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.

Abstract: A bladed disk for a gas turbine engine is provided. The bladed disk includes a rotor disk, a plurality of rotor blades, and an interlocking transition zone. The rotor disk includes a plurality of fused layers of a first material formed via additive manufacturing and defines an outer rim. The plurality of rotor blades includes a plurality of fused layers of a second material formed via additive manufacturing. The interlocking transition zone includes a plurality of projections alternately extending from the outer rim of the rotor disk and the plurality of rotor blades, respectively, to undetachably couple the rotor disk and the plurality of rotor blades.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide an integrated ceramic filter. These integrated core-shell investment casting molds also provide filament structures corresponding to cooling hole patterns on the surface of the turbine blade or stator vane, which provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine as or stator vane, which provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide filament structures corresponding to cooling hole patterns on the surface of the turbine blade or stator vane, which provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds that provide a filament structure corresponding to a cooling hole pattern in the surface of the turbine blade or stator vane, which provide a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: The present disclosure generally relates to integrated core-shell investment casting molds including a main core portion, a core tip portion, and a shell portion with at least one cavity between the core portion and the shell portion. The cavity defines the shape of a cast component upon casting and removal of the ceramic mold. These molds also provide filament structures corresponding to cooling hole patterns in the surface of the turbine blade or the stator vane, which provide a leaching pathway for the core portion after metal casting. At least two ceramic tip filaments connect the core tip portion and the shell portion and eliminate the need for tip pins or a shell lock to hold the tip plenum core in place during casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.

Abstract: Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.

Abstract: Methods of making metal objects are provided. These methods generally involve adding a metal powder slurry into a sacrificial mold, such as a mold made by three dimensional printing, and heating the slurry/mold mixture. The heating steps may include curing the slurry to make a green part inside the mold, debinding to burn off the mold and binder to make a brown part, sintering, and hot isostatic pressing. Metal products, such as aircraft engine parts, are also provided.

Abstract: A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.

Abstract: Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone comprising a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.