A method of making an airfoil includes making a refractory metal core that defines an interior of the airfoil by a tomo-lithographic process, making a mold that defines an exterior of the airfoil, inserting the refractory metal core into the mold, and pouring an airfoil material between the refractory metal core and the mold to cast the airfoil.

A method of making a composite core includes forming first and second cores of refractory metal and ceramic material. Each of the first and second cores is formed with two layers of a material. The layers are bonded together to form a laminate master pattern, and a flexible mold is formed around the pattern. The pattern is removed from the flexible mold, and slurry material, either pulverulent refractory metal material or ceramic material, is poured into the flexible mold. The slurry material is sintered to form each core. The first core is used as an insert while making the second core to create a final composite core.

A method of forming an airfoil, includes forming a hybrid skin core, a tip flag core, and a trailing edge core. The hybrid skin core, tip flag core, and trailing edge core are connected to form a first core portion. A leading edge core and a serpentine core are formed. The first core portion, the leading edge core, and the serpentine core are assembled together to form an airfoil core. An airfoil is formed around the airfoil core.

A method for casting a blade, the blade with an airfoil having: a tip having at least one of a tip pocket and a tip shelf. Each said at least one of a tip pocket and a tip shelf having a base surface and a sidewall surface. The method includes forming a shell, the forming of the shell including shelling a pattern having at least one ceramic casting core; and casting in the shell, the shell having a first portion formed by the at least one ceramic casting core and a second potion formed by applied shell material. For at least a first tip pocket or tip shelf of the least one of a tip pocket and a tip shelf, the at least one ceramic casting core molds the base surface and the sidewall surface and an adjacent portion of at least one of the pressure side and the suction side spanwise inboard of the base surface.

The present invention relates to a multicore and a method of manufacturing a hollow product using the multicore enabling a hollow of a molded product to be molded more easily by casting and a quality problem to be addressed, and the multicore includes a first core, being made of a water-insoluble material, having a hollow formed in the first core and, having an opening formed at both ends of the first core so that the hollow is exposed to the outside through the opening, a second core, being made of a water-soluble material and disposed inside the hollow, and a coating layer, being configured to surround the first core to prevent the first core and the second core from being exposed to an outside, wherein the first core includes a plurality of spaces to allow a fluid supplied to an interior of the first core to flow toward the second core.

The present invention relates to a core for hollow product manufacture including a multilayer filling material, which may be used in forming a cooling water circulation channel through which a fluid such as cooling water may pass, and a method of manufacturing a hollow product using the core, and the core includes a pipe, having a hollow formed in the pipe and an opening formed at both ends of the pipe so that the hollow is exposed to the outside through the opening, a first support member, being disposed inside the hollow and having a space formed in the first support member, a second support member, being disposed in the space, and a melting bar, passing through the second support member in a longitudinal direction of the melting bar, wherein the melting bar melts and forms a space in the second support member when the melting bar is heated.

A gas turbine engine component includes a structure including spaced apart first and second exterior walls that extend in a first direction to an endwall. The first and second exterior walls are joined at the endwall to provide a cooling cavity. A wishbone baffle is arranged in the cooling cavity and includes first and second interior walls respectively adjacent to the first and second exterior walls. The first and second interior walls extend in the first direction to and are joined by an apex to provide a first cavity. The wishbone baffle separates the first cavity from a second cavity provided between the apex and the endwall.

A coupler having a support provided through the body of the coupler and a plurality of openings in the coupler which are configured as open cavities. The coupler structure includes a shank that has a vertical support as well as lateral support. The coupler may be configured with a double I-beam structure with openings into the shank. Cores that may be fixed to the mold may be used to form the coupler and produce the openings in the shank.

A mold assembly for use in forming a component having an outer wall of a predetermined thickness includes a mold and a jacketed core. The jacketed core includes a jacket that includes a first jacket outer wall coupled against an interior wall of the mold, a second jacket outer wall positioned interiorly from the first jacket outer wall, and at least one jacketed cavity defined therebetween. The at least one jacketed cavity is configured to receive a molten component material therein. The jacketed core also includes a core positioned interiorly from the second jacket outer wall. The core includes a perimeter coupled against the second jacket outer wall. The jacket separates the perimeter from the interior wall by the predetermined thickness, such that the outer wall is formable between the perimeter and the interior wall.

A core element of an investment core for use in a casting process used to produce an airfoil includes an investment core body, an extension connected to and protruding from the investment core body, and a connection portion connected to the investment core body and to the extension. The investment core body comprises a ceramic material. A shape of the extension comprises a tube with a centerline axis passing through a center of the extension. A shape of a cross-section of the extension taken along a plane perpendicular to the extension centerline axis comprises an ellipse. The extension is connected to the investment core body by the connection portion.