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 core for an investment casting process in which a component to be cast has an internal passageway, the internal passageway being provided by the core. A first core passage having a first point and a second point and including no straight path between the first point and the second point; a first core bridge which extends away from the first core passage between the first and second points, and has a first pillar and a second pillar which connect to the first and second points respectively, and a bridge portion which extends between the first and second pillars; wherein the first pillar has a core inlet portion having a thickness at the first point and the second pillar has a thickness at the second point, the thickness of the core inlet portion at the first point being less than the thickness of the second pillar at the second point.

A core structure for a providing a cooling passage in a gas turbine engine includes a core body that has a first cooling passage core. The first cooling 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.

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 casting article according to another exemplary aspect of the present disclosure includes, among other things, a circuit forming portion including an interior channel and an outer shell body that surrounds the interior channel. An engineered failure feature is formed in the outer shell body and is configured to increase compressibility of the casting article during a casting process.

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.

In a casting device of the present invention, positions of discharge ends discharging cooling gas, of respective gas supply nozzles are adjusted in response to movement of a mold. This makes it possible to stably achieve high cooling performance for the mold by blowing of the cooling gas. To adjust the positions of the respective discharge ends, the gas supply nozzles are advanced or retreated, or are expanded or contracted. Further, a cooling chamber may include a radiation cooling portion that cools the mold by radiation, and the radiation cooling portion is disposed below the gas supply nozzles that are provided directly below a heat shielding body partitioning a heating chamber and the cooling chamber.

In one example, a sand core for use in a sand casting process includes a core body including a sand composition, the sand composition including sand and a binder; and a burnable fuse extending within the core body along a path and out of a surface of the core body, wherein the burnable fuse is configured such that when the fuse is ignited, the fuse burns within the core body to substantially remove the fuse and form a venting tunnel along the path within the core body with an opening in the surface.

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

A method of forming a component having an internal passage defined therein includes positioning a jacketed core with respect to a mold. The jacketed core includes a hollow structure formed from a first material, and an inner core formed from an inner core material disposed within the hollow structure. The method also includes introducing a component material in a molten state into a cavity of the mold, such that the component material in the molten state at least partially absorbs the first material from a portion of the jacketed core within the cavity. The method further includes cooling the component material in the cavity to form the component, and removing the inner core material from the component to form the internal passage.