Abstract: A method is provided for manufacturing a component. This method includes additively manufacturing a crucible for casting of the component. A metal material is directionally solidified within the crucible to form a metal single crystal material. A sacrificial core is removed to reveal a metal single crystal component with internal passageways. A component is provided for a gas turbine engine that includes a metal single crystal material component with internal passageways. The metal single crystal material component was additively manufactured of a metal material concurrently with a core that forms the internal passageways. The metal material was also remelted and directionally solidified.

Abstract: A method for forming an investment casting core comprises cutting a patterned core precursor from refractory metal-based sheet. The cutting forms recast along the cuts. An oxide is grown on non-recast areas. The recast is substantially chemically removed but substantially leaving the oxide. The core precursor may then be shaped.

Abstract: A substrate is coated by applying an essentially pure aluminum first layer to a surface of the substrate. At least a first portion of the first layer is oxidized so as to provide a protective coating of desired properties. The substrate may be a refractory metal-based investment casting core.

Abstract: An impregnated fired porous alumina-based ceramic core for use in an investment shell mold in the casting of molten metals and alloys wherein the core is impregnated with yttria to improve core creep resistance at elevated casting temperatures and times.

Abstract: A wax article pattern having a cavity corresponding to a cavity in a metal article is provided. The cavity in the wax article pattern is filled with a slurry of ceramic core material. The slurry of ceramic core material is solidified to form a core. The wax article pattern is enclosed by ceramic mold material. The ceramic mold material is solidified to form a mold. The wax pattern is removed from the mold to leave an article mold cavity. The article mold cavity is filled with molten metal which is solidified to form the metal article. A passage in the metal article may be formed by a pin which extends from the wax article pattern into the cavity in the wax article pattern and is enclosed by the slurry of ceramic core material.

Abstract: The method of casting a plate type recuperative heat exchange envelope that encloses a hollow space therein in a single casting operation. A sand core with a heat sensitive binder therein defines the hollow space within the envelope. The sand core is supported by end extensions and lateral protuberances which rest on the sides of a sand mold to provide a space therebetween that is subsequently filled with molten metal to comprise an envelope casting. Lateral openings through the envelope casting produced by the lateral protuberances and end openings produced by the end extensions provide passageways for venting gases produced within the sand core during the casting operation, and after completion of the casting operation the same openings in the envelope assist in the removal of the sand core therefrom. The lateral openings are subsequently plugged while the end openings are maintained open to direct the flow of fluid therethrough.

Abstract: Hand patching of recesses in the side walls of a sand mold, intended to receive a core, is avoided by filling the recess, after the core is emplaced with a complemental pre-molded cover.