Abstract: A support and air mixer includes an inner annular member, an outer annular member shaped and positioned such that an annular air gap is formed between the inner annular member and the outer annular member, and a plurality of air mixing members, each air mixing member having a mixing passageway therethrough and each air mixing member having an inner portion connected to the inner annular member, an outer portion connected to the outer annular member, and first and second opposing side portions interconnecting the inner and outer portions and the inner and outer annular members such that the mixing passageway is in fluid communication with the annular air gap.

Abstract: A core assembly including two cores is used to manufacture a blade. The first core has an outer surface shaped to complement the tip wall bottom surface. The second core has a tip surface, a side surface, and a protrusion or a depression. The tip surface is shaped to complement at least a portion of the tip wall top surface and is configured to be disposed proximate the first core. The side surface is shaped to complement at least a portion of the side wall, and the protrusion extends from the second core side surface to contact at least a portion of the ceramic mold inner surface. In embodiments employing a depression, the depression is formed in the side surface.

Abstract: A support and air mixer includes an inner annular member, an outer annular member shaped and positioned such that an annular air gap is formed between the inner annular member and the outer annular member, and a plurality of air mixing members, each air mixing member having a mixing passageway therethrough and each air mixing member having an inner portion connected to the inner annular member, an outer portion connected to the outer annular member, and first and second opposing side portions interconnecting the inner and outer portions and the inner and outer annular members such that the mixing passageway is in fluid communication with the annular air gap.

Abstract: Methods for rapid prototype casting metal components, wherein the metal components are cast in a secondary ceramic mold, the secondary ceramic mold is cast in a primary mold, and the primary mold is formed by rapid prototyping or rapid manufacturing. The secondary ceramic mold may comprise a one-piece integral shell and core(s), and the metal components may have at least one hollow portion or void therein, such as a hollow airfoil for a gas turbine engine.

Abstract: A core assembly including two cores is used to manufacture a blade. The first core has an outer surface shaped to complement the tip wall bottom surface. The second core has a tip surface, a side surface, and a protrusion or a depression. The tip surface is shaped to complement at least a portion of the tip wall top surface and is configured to be disposed proximate the first core. The side surface is shaped to complement at least a portion of the side wall, and the protrusion extends from the second core side surface to contact at least a portion of the ceramic mold inner surface. In embodiments employing a depression, the depression is formed in the side surface.

Abstract: A method of modifying a turbine nozzle area comprises depositing a thermal barrier coating (TBC) on the nozzle endwalls to provide a minimum nozzle area, evaluating an airflow through the nozzle, and machining the TBC to increase the nozzle area. Adjacent segment area variation may be minimized, improving engine reliability by reducing the aerodynamic excitation to the down stream blade.

Abstract: A turbine shroud assembly includes forward and aft hangers, an axisymmetric plenum assembly, ceramic shroud segments, ceramic spacers, and forward and aft rope seals. The plenum assembly supplies impingement cooling to the shroud and the hangers. The impingement cooling to the forward and aft hangers is controlled independently to improve blade tip clearance. The rope seals are radially inward from the hangers and reduce cooling flow leakage. The turbine shroud assembly can operate in a higher temperature environment using less cooling flow than the prior art.

Abstract: A robust multiple-walled, multi-pass, high cooling effectiveness cooled turbine vane or blade designed for ease of manufacturability, minimizes cooling flows on highly loaded turbine rotors. The vane or blade design allows the turbine inlet temperature to increase over current technology levels while simultaneously reducing turbine cooling to low levels. A multi-wall cooling system is described, which meets the inherent conflict to maximize the flow area of the cooling passages while retaining the required section thickness to meet the structural requirements. Independent cooling circuits for the vane or blade's pressure and suction surfaces allow the cooling of the airfoil surfaces to be tailored to specific heat load distributions (that is, the pressure surface circuit is an independent forward flowing serpentine while the suction surface is an independent rearward flowing serpentine). The cooling air for the independent circuits is supplied through separate passages at the base of the vane or blade.

Abstract: A robust multiple-walled, multi-pass, high cooling effectiveness cooled turbine vane or blade designed for ease of manufacturability, minimizes cooling flows on highly loaded turbine rotors. The inventive vane or blade design allows the turbine inlet temperature to increase over current technology levels while simultaneously reducing turbine cooling to low levels. The invention comprises a complex multi-wall cooling system, which meets the inherent conflict to maximize the flow area of the cooling passages while retaining the required section thickness to meet the structural requirements. Independent cooling circuits for the vane or blade's pressure and suction surfaces allow the cooling of the airfoil surfaces to be tailored to specific head load distributions (that is, the pressure surface circuit is an independent forward flowing serpentine while the suction surface is an independent rearward flowing serpentine).

Abstract: A method for making a bimetallic ring seal having a nickel core covered by a first layer of platinum having a inner dense portion and a second outer portion both of which plastically deform in the presence of a load. The method includes the step of applying a porous layer of platinum over the dense layer by electroless plating in a platinum bath comprising 0.8-1.2 gram/liter platinum as diammine dinitrite salt Pt(NH3)2(NO2)2, 50-100 milliliter/liter of 25% ammonium hydroxide NH4OH; and 0.3-1.5 gram/liter hydrazine hydrate N2H4—H2O, at a temperature in the range of 75-90° C. and at a plating rate in the range of 0.5-3.0 micron/hour and then plastically deforming the ring seal under load.