A method of providing a tool with a conformal cooling passage includes rough machining a cavity generally corresponding to a manufactured part shape using CAD data. Conformal cooling slots are cut in the cavity using the CAD data. The conformal cooling slots are welded shut using the CAD data to provide conformal cooling passages. A class A surface is machined over the conformal cooling passage and corresponds to a finished manufactured part shape using the CAD data.

An apparatus and method for forming a film hole in an outer wall of an airfoil. The film hole includes a blind opening adjacent the interior of the airfoil and a hole adjacent the exterior of the airfoil. The blind opening fluidly couples to the hole to form the film hole for providing a volume of fluid as a surface cooling film along the exterior of the outer wall.

An apparatus and method for forming a film hole in an outer wall of an airfoil. The film hole includes a blind opening adjacent the interior of the airfoil and a hole adjacent the exterior of the airfoil. The blind opening fluidly couples to the hole to form the film hole for providing a volume of fluid as a surface cooling film along the exterior of the outer wall.

A method of preparing a casting article for use in manufacturing a gas turbine engine part according to an exemplary aspect of the present disclosure includes, among other things, communicating a powdered material to an additive manufacturing system and preparing a casting article that includes at least one trunk and a skin core that extends from the at least one trunk out of the powdered material. A casting article is also disclosed.

An apparatus and method for forming a film hole in an outer wall of an airfoil. The film hole includes a blind opening adjacent the interior of the airfoil and a hole adjacent the exterior of the airfoil. The blind opening fluidly couples to the hole to form the film hole for providing a volume of fluid as a surface cooling film along the exterior of the outer wall.

An apparatus and method for forming a film hole in an outer wall of an airfoil. The film hole includes a blind opening adjacent the interior of the airfoil and a hole adjacent the exterior of the airfoil. The blind opening fluidly couples to the hole to form the film hole for providing a volume of fluid as a surface cooling film along the exterior of the outer wall.

A mold molding method includes a binder reaction amount calculation step of calculating a reaction amount C(, t.sub.i) [wt %] (i=1, 2) of a binder, a specimen room temperature compressive strength calculation step of calculating room temperature compressive strength .sub.c(, t) [MPa] of a specimen, a mold room temperature compressive strength prediction step of predicting room temperature compressive strength .sub.ca(, t) of the mold in advance, and a mold room temperature compressive strength extraction step of extracting room temperature compressive strength .sub.ce(, t) of the mold. When the mold is actually molded, the model is removed just after elapse of the time t.sub.1, as one of the molding condition parameters which satisfies the room temperature compressive strength .sub.ce(, t).

A mold molding method includes a binder reaction amount calculation step of calculating a reaction amount C(, t.sub.i) [wt %] (i=1, 2) of a binder, a specimen room temperature compressive strength calculation step of calculating room temperature compressive strength .sub.c(, t) [MPa] of a specimen, a mold room temperature compressive strength prediction step of predicting room temperature compressive strength .sub.ca(, t) of the mold in advance, and a mold room temperature compressive strength extraction step of extracting room temperature compressive strength .sub.ce(, t) of the mold. When the mold is actually molded, the model is removed just after elapse of the time t.sub.1, as one of the molding condition parameters which satisfies the room temperature compressive strength .sub.ce(, t).

A mould for use in manufacturing a single-crystal component by metal casting and epitaxial growth, includes a cavity in which the component is to be formed and a housing having an elliptical cross-section in which a single-crystal seed is disposed, the seed having an elliptical cross-section defined by a minor axis and by a major axis, the housing being in fluid communication with the cavity via an opening of circular cross-section through which molten metal is to flow, the single-crystal seed and the opening being centred on the same vertical axis, in which the minor axis and the major axis of the cross-section of the seed are oriented as a function of the secondary crystallographic orientations of the single-crystal forming the single-crystal seed.

A method of preparing a casting article for use in manufacturing a gas turbine engine part according to an exemplary aspect of the present disclosure includes, among other things, communicating a powdered material to an additive manufacturing system and preparing a casting article that includes at least one trunk and a skin core that extends from the at least one trunk out of the powdered material.