A hybrid core for manufacturing a cast component, the hybrid core including a sand core portion having an exterior shape configured to define an interior feature of the cast component. The hybrid core also includes a metal chill element embedded within the sand core portion. The metal chill element is configured to locally absorb heat energy from the cast component during cooling of the cast component and solidification thereof. The metal chill element is constructed and arranged within the sand core portion to be removed during shake out from the cast component subsequent to the solidification thereof. A system and a method for manufacturing a cast component using such a hybrid core are also envisioned.

A component for a gas turbine engine includes a trailing edge tip corner that at least partially defines a trailing edge cavity and a multiple of corner features within the trailing edge cavity, the multiple of corner features splayed along the trailing edge tip corner.

A component according to an exemplary aspect of the present disclosure includes, among other things, a first cavity, a second cavity and a rib between the first cavity and the second cavity, the rib including a first rib surface that is substantially flat and a second rib surface that is tapered.

A gas turbine engine according to an example of the present disclosure includes, among other things, a rotor and a vane spaced axially from the rotor, and a blade outer air seal spaced radially from the rotor. At least one of the rotor and the vane includes an airfoil section extending from a platform. At least one of the airfoil section, the platform and the blade outer air seal includes a first cavity extending in a first direction, the first cavity defining a reference plane along a parting line formed by a casting die, and a plurality of trip strips including a first set of trip strips distributed in the first direction along a surface of the first cavity and on a first side of the reference plane, each of the plurality of trip strips defining a respective groove axis extending longitudinally between a first end and an opposed, second end of a respective one the plurality of trip strips, and the groove axes being oriented with respect to a pull direction of the casting die. A casting core and method for fabricating a gas turbine engine component is also disclosed.

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.

Aspects of the disclosure are directed to treating a substrate, the substrate including at least one of a refractory metal or a ceramic material, and depositing a media onto the treated substrate to generate a casting core. Embodiments include a fixture, a substrate located on the fixture, the substrate including at least one of a refractory metal or a ceramic material, and a delivery head that deposits media onto the substrate to generate a casting core. Aspects are directed to a core configured for casting a component, the core comprising: a substrate that includes at least one of a refractory metal or a ceramic material, and media deposited on the substrate, the media having a dimension within a range of between 0.5 and 100 micrometers.

An airfoil core includes a first core portion that has a hybrid skin core, a tip flag core, and a trailing edge core. A second core portion has a serpentine core and a leading edge core.

A method and casting core for forming a landing for welding a baffle inserted into an airfoil are disclosed, wherein the baffle landing of the blade or vane is formed in investment casting by the casting core rather than by wax, reducing tolerances and variability in the location of the baffle inserted into the cooling cavity of airfoil when the baffle is welded to the baffle landing.

A method of manufacturing protruding cast in features (10). At least one core insert (12) is manufactured using small particle sizes. A bulk core body is manufactured using large particle sizes. The at least one core insert (12) and bulk core body are fully fired separately. The at least one core insert (12) is bonded with the bulk core body.

A mold assembly cell for sand mold production comprising a turntable wherein sand cores and other mold parts (which together cooperate to define the casting cavity of the sand mold) are automatically and progressively assembled following a sequential pre-programmed schedule by programmable robots located in proximal relationship with the turntable and a core shooting machine. The assembly turntable rotates clockwise or counterclockwise to permit placement of progressively more-complete mold packages in each of at least three assembly stations to allow the robots to reach the molds being assembled at different angles for simultaneously setting the sand cores and other parts of the mold according to said pre-programmed assembly schedule. Also a mold assembly line comprising a plurality of the foregoing assembly cells to form sand molds for casting complex-geometry aluminum parts, such as aluminum engine blocks and cylinder heads, with greater flexibility, efficiency and productivity.