An airfoil for a gas turbine engine according to an example of the present disclosure includes an airfoil section extending in a radial direction from a root section to a tip portion. The airfoil section has an external wall and an internal wall. The airfoil section establishes an internal cooling arrangement including a first cooling passage having a first section and a tip flag section. The tip flag section extends in the chordwise direction along the tip portion from the first section. The first section includes a plurality of branched paths established by at least one turning vane.

A method for the thermal treatment of a component, in particular a metal powder injection molded component (MIM component) including a nickel base alloy, wherein, after sintering, in particular immediately after sintering, in the injection molding process, the component is exposed for a predetermined holding time to at least one treatment temperature below the sintering temperature. A component, in particular an MIM component, and to an aircraft engine.

A turbine blade including a root carrying an impeller terminated by a tip in the form of a squealer tip. This impeller also includes a serpentine median circuit, including a first radial pipe collecting air at the root and that is connected by a first bend to a second radial pipe that is connected by a second bend to a third radial pipe, a cavity under the squealer tip running along the pressure side wall, extending from a central region of the tip to the trailing edge, and a radial central pipe collecting air at the root extending between at least two of the three pipes of the median circuit and directly supplying the cavity under the squealer tip.

A core is provided for fabricating a blade to include an airfoil. The airfoil includes pressure and suction surfaces, leading and trailing edges extending along the pressure and suction surfaces and a tip shelf with a first sweep configuration and a wall. The core includes channel sections configured to form internal channels within the airfoil by casting processes and tip rods extending from respective portions of the channel sections proximate to a tip shelf location. The respective portions of the channel sections have a second sweep configuration corresponding to the first sweep configuration. The tip rods are configured to extend through the wall at an angle of about 5-12 degrees inclusive relative to a normal angle of the wall during the casting processes to form through-holes angled at about 5-12 degrees inclusive in the wall.

A core structure for a providing a cooling passage in a gas turbine engine includes a core body that has a first passage core. The first passage core has a first width in a chord-wise direction near a first wall. A second width in the chord-wise direction near a second wall. A third width in the chord-wise direction between the first and second walls. The third width being smaller than the first and second widths to form an hourglass shape.

Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.

A method of manufacturing a cooled gas turbine component includes forming a core with an outer surface. The outer surface includes a core feature. The method also includes casting an outer wall of an airfoil about the core. The outer wall has an exterior surface and an interior surface. The interior surface includes a shaped inlet portion that corresponds to the core feature. Moreover, the method includes forming an outlet portion through the outer wall to fluidly connect the outlet portion to the shaped inlet portion. The shaped inlet portion and the outlet portion cooperatively define a cooling aperture through the outer wall.

A cast component includes a body and a passage defined within the body. The passage includes a first portion, a second portion and a turn portion fluidly coupling the first and second portions. The turn portion includes a first surface and a second surface. A surface anti-freckling element extends through the turn portion of the passage from the first surface to the second surface of the turn portion. The element separates the passage in the turn portion into a first sub-passage and a second sub-passage. The element is formed by an opening in a removable core used during the casting that includes a surface anti-freckling opening at the location of the element that provides a path for low-density liquid alloy to flow through a core turn portion of the core to reduce surface freckling of the passage in the body of the component.

A method of manufacturing a TiAl alloy impeller includes a blank preparation step in which a blank of the TiAl alloy impeller is prepared, wherein the blank has a shaft portion and a plurality of blades, and a thickness of an outer edge of each of the blades of the blank is set so as to be larger than a thickness of an outer edge of a blade of the TiAl alloy impeller, and an additional work step in which an additional work is performed on each of the blades of the blank. In the additional work step, the additional work is performed on a first surface of a portion that includes at least the outer edge of each of the blades or the first surface and a second surface of the portion thereof.

A method includes casting a metallic material (56) in a mold (20) containing a core, the core having a substrate (40, 44) coated with a coating (42). A removing of the metallic material from the mold and decoring leaves a casting having a layer formed by the coating. The coating has a ceramic having a porosity in a zone (50) near the substrate less than a porosity in a zone (52) away from the substrate.