A method of forming a casting with a flow passage may include filling a tubular pipe with a filler to form a smart core; inserting the smart core into a mold having a cavity corresponding to a shape of the casting to be formed; injecting a molten metal into the cavity through a casting process; and removing the filler from the smart core, wherein a hardness of the tubular pipe is 70 Hv or more.

A method of making a turbine airfoil includes generating an airfoil core (14) that includes a core exit along an extended portion (28) of the trailing edge (32) outside of the airfoil part geometry. Float points (12) are positioned along the extended portion (28) of the airfoil core (14). Each float point (12) includes a float feature (34) that includes a localized radially straight surface (42) extending out and creating a gap (18) between the airfoil core (14) and the mold shell (16).

A gas turbine engine according to an example of the present disclosure includes, among other things, a plurality of blade outer air seals and a plurality of airfoils, at least one of seals and airfoils including at least one cooling passage. The cooling passage includes a first wall and an opposed second wall bounding the cooling passage, a surface contour of the first wall having a plurality of first surface features and a surface contour of the second wall having a plurality of second surface features. The first surface features and the second surface features are arranged such that a width of the cooling passage varies along a length of the cooling passage defined by the first surface features and the second surface features. The first surface features have a first profile, and the second surface features have a second, different profile. A casting core for forming cooling passages in an aircraft component is also disclosed.

A method of forming a casting with a flow passage may include forming a core obtained by filling a tubular pipe with a filler; inserting the core into a mold having a cavity corresponding to a shape of the casting to be formed; performing a casting process by injecting molten metal into the cavity; and removing the filler from the core, wherein the casting process is performed through a high-pressure casting process.

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.

A holding device for holding a casting core in a casting mold, especially in a die-casting mold, includes a plurality of clamping sections which are positioned in relation to each other in such a way that a clamping region for a casting core is formed.

A gas turbine engine according to an example of the present disclosure includes, among other things, a plurality of blade outer air seals and a plurality of airfoils, at least one of seals and airfoils including at least one cooling passage. The cooling passage includes a first wall and an opposed second wall bounding the cooling passage, a surface contour of the first wall having a plurality of first surface features and a surface contour of the second wall having a plurality of second surface features. The first surface features and the second surface features are arranged such that a width of the cooling passage varies along a length of the cooling passage defined by the first surface features and the second surface features. The first surface features have a first profile, and the second surface features have a second, different profile. A casting core for forming cooling passages in an aircraft component is also disclosed.

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 method is provided for casting a component. Accordingly, a casting core is provided within a cavity of a component mold. The casting core defines an inner component shape and includes a core wall. The core wall defines a core outer surface and a core inner surface disposed opposite the core outer surface. The core inner surface defines a core cavity. The casting core also includes a removal facilitation feature. The component is cast within the cavity of the component mold with the casting core positioned therein. The cast component is removed from the component mold and the casting core is removed from the cast component.

A casting ceramic core includes a ceramic structure having at least one through hole and a plurality of features extending from a main ceramic body. The ceramic body defines a negative space for a casting and a plurality of aligned fibers extending a substantial length of at least one casting feature.