An investment casting process for manufacturing a cast component is provided. The investment casting process includes forming a core, casting the cast component about the core such that a core positioning feature provides a location of an anticipated pilot hole in the cast component, removing the core from the cast component once the casting is completed, locating, forming and sizing a pilot hole to form a resized pilot hole that can receive a sealing plug and installing the sealing plug into the resized pilot hole.

A method for manufacturing a ceramic core blank intended for the manufacture of hollow turbomachine blades using the technique of lost wax casting, the blank being manufactured by additive manufacture and comprising at least one first part intended to form the cavities of the hollow blades and at least one second part configured to allow the positioning of the core in a wax mold, the second part and the first part being positioned and held with respect to one another by means of a junction portion interposed between the first part and the second part, at least one through orifice extending through the second part, the junction portion and the first part, a first end of the through orifice opening to an outer face of the second part, and a second end of the through orifice opening to an outer face of the first part.

Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

Partial integrated core-shell investment casting molds that can be assembled into complete molds are provided herein. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. Core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold are also provided herein.

A method for manufacturing a ceramic core blank intended for the manufacture of hollow turbomachine blades using the technique of lost wax casting, the blank being manufactured by additive manufacture and comprising at least one first part intended to form the cavities of the hollow blades and at least one second part configured to allow the positioning of the core in a wax mold, the second part and the first part being positioned and held with respect to one another by means of a junction portion interposed between the first part and the second part, at least one through orifice extending through the second part, the junction portion and the first part, a first end of the through orifice opening to an outer face of the second part, and a second end of the through orifice opening to an outer face of the first part.

A cast component having reduced cross flow linking cavities and method of casting may include a body. The body may define a plurality of internal flow channels. The plurality of internal flow channels may include a first internal flow channel and a second internal flow channel. The cast component may also include a plurality of linking cavities obstructing unintended fluid communication between the first internal flow channel and the second internal flow channel through the plurality of linking cavities.

A cast component having reduced cross flow linking cavities and method of casting may include a body. The body may define a plurality of internal flow channels. The plurality of internal flow channels may include a first internal flow channel and a second internal flow channel. The cast component may also include a plurality of linking cavities obstructing unintended fluid communication between the first internal flow channel and the second internal flow channel through the plurality of linking cavities.

A leachable casting core and method of manufacture may include a plurality of legs configured to establish a plurality of internal flow channels of a cast component. Tie bars, with a first tie bar end and a second tie bar end opposite thereof, may couple to at least two of the plurality of legs. At least one of the tie bars may be oriented to form a linking cavity within the cast component between the internal flow channels. The linking cavity may serve as an obstruction to fluid communication through the linking cavity.

A leachable casting core and method of manufacture may include a plurality of legs configured to establish a plurality of internal flow channels of a cast component. Tie bars, with a first tie bar end and a second tie bar end opposite thereof, may couple to at least two of the plurality of legs. At least one of the tie bars may be oriented to form a linking cavity within the cast component between the internal flow channels. The linking cavity may serve as an obstruction to fluid communication through the linking cavity.

The present disclosure generally relates to partial integrated core-shell investment casting molds that can be assembled into complete molds. Each section of the partial mold may contain both a portion of a core and portion of a shell. Each section can then be assembled into a mold for casting of a metal part. The partial integrated core-shell investment casting molds and the complete molds may be provided with filament structures corresponding to cooling hole patterns on the surface of the turbine blade or the stator vane, which provides a leaching pathway for the core portion after metal casting. The invention also relates to core filaments that can be used to supplement the leaching pathway, for example in a core tip portion of the mold.