Abstract: A method of manufacturing a gas turbine engine component includes providing a core having a brittle feature, supporting the feature with a first meltable material, arranging the core with the first meltable material in a first mold, and surrounding the core and the first meltable material with a second meltable material to provide a component shape. The method also includes coating the second meltable material with a refractory material to produce a second mold, removing the first and second meltable material, and casting a component in the second mold.

Abstract: The present disclosure is directed to a refractory metal core for use in forming varying thickness microcircuits in turbine engine components, a process for forming the refractory metal core, and a process for forming the turbine engine components. The refractory metal core is used in the casting of a turbine engine component. The core is formed by a sheet of refractory metal material having a curved trailing edge portion integrally formed with a leading edge portion.

Abstract: The present disclosure is directed to a refractory metal core for use in forming varying thickness microcircuits in turbine engine components, a process for forming the refractory metal core, and a process for forming the turbine engine components. The refractory metal core is used in the casting of a turbine engine component. The core is formed by a sheet of refractory metal material having a curved trailing edge portion integrally formed with a leading edge portion.

Abstract: An investment casting core combination includes a metallic casting core and a ceramic feedcore. A first region of the metallic casting core is embedded in the ceramic feedcore. A mating edge portion of the metallic casting core includes a number of projections. The first region is along at least some of the projections. A number of recesses span gaps between adjacent projections. The ceramic feedcore includes a number of compartments respectively receiving the metallic casting core projections. The ceramic feedcore further includes a number of portions between the compartments and respectively received in the metallic casting core recesses.

Abstract: The present disclosure is directed to a refractory metal core for use in forming varying thickness microcircuits in turbine engine components, a process for forming the refractory metal core, and a process for forming the turbine engine components. The refractory metal core is used in the casting of a turbine engine component. The core is formed by a sheet of refractory metal material having a curved trailing edge portion integrally formed with a leading edge portion.

Abstract: A gas turbine engine has a turbine blade having a tip cap to close off internal cooling passages. The tip cap is formed with a plurality of purge holes, with there being at least two rows of purge holes. The increased number of purge holes spreads the cooling air outwardly across more of the surface area of the tip cap, and provides the tip cap with a better ability to withstand the extreme temperatures it faces in use.

Abstract: An investment casting core combination includes a metallic casting core and a ceramic feedcore. A first region of the metallic casting core is embedded in the ceramic feedcore. A mating edge portion of the metallic casting core includes a number of projections. The first region is along at least some of the projections. A number of recesses span gaps between adjacent projections. The ceramic feedcore includes a number of compartments respectively receiving the metallic casting core projections. The ceramic feedcore further includes a number of portions between the compartments and respectively received in the metallic casting core recesses.

Abstract: A gas turbine engine is provided with an airfoil component that is disclosed as a turbine blade. Internal cooling passages circulate air within the blade. An impingement rib separates a cooling air channel from a pedestal array, and includes cross-over holes to meter the flow of air into the pedestal array. A lower end of the impingement rib is split to reduce stress concentrations between the impingement rib and a platform. Further, the pedestals adjacent to the lower end of the impingement rib are formed to be stubs, which do not extend entirely across a width of the blade. The disclosed structure reduces the stress concentration at an area where the impingement rib meets the platform.

Abstract: A gas turbine engine has a turbine blade having a tip cap to close off internal cooling passages. The tip cap is formed with a plurality of purge holes, with there being at least two rows of purge holes. The increased number of purge holes spreads the cooling air outwardly across more of the surface area of the tip cap, and provides the tip cap with a better ability to withstand the extreme temperatures it faces in use.

Abstract: A blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a proximal end joining the first end portion; a main body portion; and a free distal portion. Second legs each have: a proximal end joining the second end portion; a main body portion; and a free distal portion.

Abstract: A blade outer air seal (BOAS) casting core has first and second end portions and a plurality of legs. Of these legs, first legs each have: a proximal end joining the first end portion; a main body portion; and a free distal portion. Second legs each have: a proximal end joining the second end portion; a main body portion; and a free distal portion.

Abstract: In a gas turbine engine, a stress relief is formed along a blade root and disk slot junction. An exemplary relief is a chamfer along the pressure side of the blade root extending forward from the aft face of the root.

Abstract: A gas turbine engine is provided with an airfoil component that is disclosed as a turbine blade. Internal cooling passages circulate air within the blade. An impingement rib separates a cooling air channel from a pedestal array, and includes cross-over holes to meter the flow of air into the pedestal array. A lower end of the impingement rib is split to reduce stress concentrations between the impingement rib and a platform. Further, the pedestals adjacent to the lower end of the impingement rib are formed to be stubs, which do not extend entirely across a width of the blade. The disclosed structure reduces the stress concentration at an area where the impingement rib meets the platform.

Abstract: A turbine blade for use in a gas turbine engine is provided. The turbine blade includes an airfoil portion having a tip end, a shroud attached to the tip end, which shroud has an outer surface, and a knife edge attached to an outer surface of the shroud. The knife edge has a pair of cutter blades disposed substantially over an axis of the airfoil portion.