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 method of producing a steel foam component includes providing a mold defining a cavity. The method also includes positioning an insert within the cavity of the mold. The insert can be configured to form a generally uniform pattern of pores within the steel foam component, and in some cases occupies at least 20% of the cavity. The method can further include pouring molten steel into the cavity, cooling the molten steel into the steel foam component, and removing the steel foam component and the insert from the mold. Steel components having internal shapes corresponding to the insert(s) are also provided.

Systems and methods are provided for a cylinder block having one or more bulkheads. The bulkheads provide a dual-wall structure that may enhance the stiffness of the cylinder block in bending and torsion. The bulkheads may also provide an oil drain to allow oil to directly drain through a hollow core of the bulkhead. An overflow outlet may be formed in an inner wall of a bulkhead. In some implementations, a cylinder block with bulkheads may increase an oil capacity of an engine.

Systems and methods are provided for a cylinder block having one or more bulkheads. The bulkheads provide a dual-wall structure that may enhance the stiffness of the cylinder block in bending and torsion. The bulkheads may also provide an oil drain to allow oil to directly drain through a hollow core of the bulkhead. An overflow outlet may be formed in an inner wall of a bulkhead. In some implementations, a cylinder block with bulkheads may increase an oil capacity of an engine.

A system including a container for holding a photosensitive medium adapted to change states upon exposure to a light source, an optical imaging system, configured to move above the container holding the photosensitive medium, and having the light source, and a control system configured to: slice a digital model of a three-dimensional object into a slice having a cross-section, generate a build cross-section by filling a two-dimensional image with one or more copies of the cross-section, add to the build cross-section a conformal lattice to fill space in the build cross-section around the one or more copies of the cross-section, and control movement of the optical imaging system above the container to cure a portion of the photosensitive medium corresponding to the build cross-section to produce a layer of a three-dimensional object.

A system including a container for holding a photosensitive medium adapted to change states upon exposure to a light source, an optical imaging system, configured to move above the container holding the photosensitive medium, and having the light source, and a control system configured to: slice a digital model of a three-dimensional object into a slice having a cross-section, generate a build cross-section by filling a two-dimensional image with one or more copies of the cross-section, add to the build cross-section a conformal lattice to fill space in the build cross-section around the one or more copies of the cross-section, and control movement of the optical imaging system above the container to cure a portion of the photosensitive medium corresponding to the build cross-section to produce a layer of a three-dimensional object.

The present disclosure is directed, in certain embodiments, a component of a mechanical apparatus. The component includes a cast body with an initial structure formed by a mold and at least one feature deposited on the cast body using a solid state additive manufacturing process, such that in combination the initial structure and the at least one feature form a complete structure of the component.

The present disclosure is directed, in certain embodiments, a component of a mechanical apparatus. The component includes a cast body with an initial structure formed by a mold and at least one feature deposited on the cast body using a solid state additive manufacturing process, such that in combination the initial structure and the at least one feature form a complete structure of the component.

A method of providing datum features on a ceramic article including the steps of providing a ceramic member having a plurality of substantially parallel holes extending into the ceramic member. Providing a plurality of tubular mounts, the cross-sectional area of each tubular mount being less than the cross-sectional area of the corresponding hole. Applying adhesive to the exterior surface of each one of the tubular mounts and inserting an adhesive covered tubular mount into each one of the holes. Providing a fixture member having a plurality of substantially parallel projections extending from predetermined positions. Positioning the ceramic member on the fixture member such that each projection locates in one of the tubular mounts and fixes the tubular mounts at the predetermined positions. The ceramic article may be removed from the fixture member or located in a machine tool using the fixture member and machining the ceramic article.

A method of providing datum features on a ceramic article including the steps of providing a ceramic member having a plurality of substantially parallel holes extending into the ceramic member. Providing a plurality of tubular mounts, the cross-sectional area of each tubular mount being less than the cross-sectional area of the corresponding hole. Applying adhesive to the exterior surface of each one of the tubular mounts and inserting an adhesive covered tubular mount into each one of the holes. Providing a fixture member having a plurality of substantially parallel projections extending from predetermined positions. Positioning the ceramic member on the fixture member such that each projection locates in one of the tubular mounts and fixes the tubular mounts at the predetermined positions. The ceramic article may be removed from the fixture member or located in a machine tool using the fixture member and machining the ceramic article.