CPC B22D 25/02 (2013.01) [B22C 1/00 (2013.01); B22C 9/04 (2013.01); B22C 9/10 (2013.01); B22C 9/103 (2013.01); B22C 9/108 (2013.01); B22C 9/18 (2013.01); B22C 9/24 (2013.01); B22D 29/001 (2013.01); F01D 5/188 (2013.01); F01D 9/041 (2013.01); F01D 25/12 (2013.01); F05D 2230/211 (2013.01); F05D 2230/232 (2013.01); F05D 2240/12 (2013.01); F05D 2240/126 (2013.01); F05D 2240/30 (2013.01); F05D 2260/201 (2013.01); F05D 2300/13 (2013.01)] | 12 Claims |
1. A method of forming a first landing and a second landing for welding a first baffle and a second baffle inserted into a cooling cavity of an airfoil comprising the steps of:
forming a casting core having a first portion in the shape of the first landing, the first portion located at one of an outer platform end or an inner platform end disposed at opposing longitudinal ends of the casting core;
forming the second portion of the casting core in the shape of the second landing, the second portion located at the other of the outer platform end or the inner platform end;
overmolding the casting core with wax to form a casting pattern having a first portion in the shape of the first landing and a second portion in the shape of the second landing;
shelling the casting pattern with a shell;
removing the casting pattern to form a void between the shell and the casting core;
pouring metal into the void to surround the casting core; and removing the shell, wherein the first landing is formed by the first portion of the casting core in the shape of the first landing and the second landing is formed by the second portion of the casting core in the shape of the second landing;
wherein the first portion includes a laterally-extending first step portion being configured to mold the first landing as a spanwise-facing surface of the airfoil relative to an airfoil span direction onto which the first baffle is welded providing a spanwise locating surface for the first baffle;
wherein the cooling cavity portion extends longitudinally between the outer platform end and the inner platform end; and
wherein the first step portion extends substantially perpendicularly laterally from the cooling cavity portion.
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7. A method of forming a first landing for welding a first baffle inserted into a cooling cavity of an airfoil and a second landing for welding a second baffle inserted into the cooling cavity comprising the steps of:
forming a casting core having a first portion in the shape of the first landing and a second portion in the shape of the second landing;
overmolding the casting core with wax to form a casting pattern having a first portion in the shape of the first landing and a second portion in the shape of the second landing;
shelling the casting pattern with a shell;
removing the casting pattern to form a void between the shell and the casting core;
pouring metal into the void to surround the casting core; and removing the shell, wherein the first landing is formed by the first portion of the casting core in the shape of the first landing and the second landing is formed by the second portion of the casting core in the shape of the second landing;
wherein the first portion is located at one of an outer platform end or an inner platform end disposed at opposing longitudinal ends of the casting core and the second portion is located at the other of the outer platform end or the inner platform end;
wherein the first portion includes a laterally-extending first step portion being configured to mold the first landing as a spanwise-facing surface of the airfoil relative to an airfoil span direction onto which the first baffle is welded providing a spanwise locating surface for the first baffle;
wherein the cooling cavity portion extends longitudinally between the outer platform end and the inner platform end; and
wherein the first step portion extends substantially perpendicularly laterally from the cooling cavity portion.
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