An example system includes a casting mold and a casting core. The casting core includes a substrate. A plurality of support structures integral with and extending from the substrate define a plurality of channels. Respective support structures of the plurality of support structures define respective contact surfaces distal from the substrate. A sacrificial composition substantially fully fills the plurality of cooling channels and leaves the respective contact surfaces substantially uncovered. An example technique includes filling the sacrificial composition in the plurality of cooling channels, and casting a cover layer onto the respective contact surfaces of the plurality of support structures.

An apparatus and method for forming a film hole in an outer wall of an airfoil. The film hole includes a blind opening adjacent the interior of the airfoil and a hole adjacent the exterior of the airfoil. The blind opening fluidly couples to the hole to form the film hole for providing a volume of fluid as a surface cooling film along the exterior of the outer wall.

An apparatus and method for forming a film hole in an outer wall of an airfoil. The film hole includes a blind opening adjacent the interior of the airfoil and a hole adjacent the exterior of the airfoil. The blind opening fluidly couples to the hole to form the film hole for providing a volume of fluid as a surface cooling film along the exterior of the outer wall.

The present disclosure discloses a production line for ceramic shell making and a method for ceramic shell making. The production line may include a conveyor chain system, a robotic arm, a slurry coating device, and a sanding device. The conveyor chain system may be configured to convey a batch of modules. The robotic arm may be configured to replace and remove one or more modules among the batch of modules relative to the conveyor chain system and hold the one or more modules during a plurality of subsequent operations. The robotic arm may be configured to be moveable to a plurality of positions each of which corresponds to one of a plurality of stations. The slurry coating device may be configured to coat the one or more modules in slurry. The sanding device may be configured to sand the one or more modules.

A casting core may include a core body and a tip comb extending from a tip region of the core body. The tip comb may be integrally formed with the core body. The tip comb may comprise a first casting pedestal and a second casting pedestal. The first casting pedestal and the second casting pedestal may define an aperture having a tapered geometry.

A fabrication method for fabricating a pattern for lost pattern casting, comprising at least one insert (10), providing at least two pattern portions (12, 14), said at least two portions being made of a material that can be eliminated, and assembling said at least two pattern portions together around at least a portion of said at least one insert in sealed manner so as to make said pattern (16).

An example system includes a casting mold and a casting core. The casting core includes a substrate. A plurality of support structures integral with and extending from the substrate define a plurality of channels. Respective support structures of the plurality of support structures define respective contact surfaces distal from the substrate. A sacrificial composition substantially fully fills the plurality of cooling channels and leaves the respective contact surfaces substantially uncovered. An example technique includes filling the sacrificial composition in the plurality of cooling channels, and casting a cover layer onto the respective contact surfaces of the plurality of support structures.

Various embodiments include methods and related systems for laser-assisted casting. Some embodiments include a method including: performing laser ablation to a preliminary wax casting model to form a modified wax model including at least one surface texture element absent from the wax casting substrate; coating the modified wax model to form a mold shape around the modified wax model; and removing the modified wax model to leave a casting mold including the at least one surface texture element.

An investment mold slurry curtain apparatus includes a slurry curtain of a slurry fluid, the slurry curtain having a length and a thickness, the length substantially greater than the thickness. The apparatus also includes an outlet configured to dispense the slurry fluid and form the slurry curtain. The investment mold slurry curtain apparatus may include and be described as an investment mold slurry coating apparatus including a conduit configured to receive a flow of a slurry fluid and an outlet operatively coupled to the conduit, the outlet configured to dispense the flow of the slurry as a curtain of the slurry.