Abstract: A method for making a turbine airfoil includes providing a mold core and an outer shell which cooperatively define a cavity in the shape of a hollow airfoil having an outer wall, a root, and a tip. A tip portion of the core extends completely through the portion of the cavity defining the tip of the airfoil. The core is restrained to prevent movement between the core and outer shell. Molten metal is introduced into the cavity and solidified to form an airfoil having at least one outer wall which defines an open tip and a hollow interior. A metallic tip cap is formed on the outer wall which substantially closes off the open tip. The tip cap may be formed by packing the airfoil with metallic powder; and laser sintering the exposed powder so as to form a tip cap which is metallurgically bonded to the outer wall.

Abstract: A method for making a turbine airfoil includes: (a) providing a mold having: (i) a core; (ii) an outer shell surrounding the core such that the core and the outer shell cooperatively define a cavity in the shape of an airfoil having at least one outer wall; and (iii) a core support extending from the core to the outer shell through a portion of the cavity that defines the at least one sidewall; (b) introducing molten metal alloy into the cavity and surrounding the core support; (c) solidifying the alloy to form an airfoil casting having at least one outer wall which has at least one core support opening passing therethrough; (d) removing the mold so as to expose the airfoil; and (e) sealing the at least one core support opening in the airfoil with a metal alloy metallurgically bonded to the at least one outer wall.