Additively manufactured casting articles for manufacturing gas turbine engine parts

Abstract

A method of preparing a casting article for manufacturing a gas turbine engine part according to an exemplary aspect of the present disclosure includes communicating a powdered material to an additive manufacturing system, the powdered material including at least one of a silica material, an alumina material, and a refractory metal material. The method includes using the additive manufacturing system to manufacture a casting article layer by layer, the casting article including a plurality of circuit forming portions, at least one of the circuit forming portions including an interior channel that establishes a hollow opening through the circuit forming portion.

What is claimed is: 
     
         1 . A method of preparing a casting article for manufacturing a gas turbine engine part, comprising the steps of:
 communicating a powdered material to an additive manufacturing system, the powdered material including at least one of a silica material, an alumina material, and a refractory metal material; and   using the additive manufacturing system to manufacture a casting article layer by layer, the casting article including a plurality of circuit forming portions, at least one of the circuit forming portions including an interior channel that establishes a hollow opening through the circuit forming portion.   
     
     
         2 . The method as recited in  claim 1 , wherein a leaching path extends between an inlet and an outlet of the interior channel. 
     
     
         3 . The method as recited in  claim 1 , wherein the step of using the additive manufacturing system includes:
 melting a first layer of the powdered material to form a first cross-sectional layer of the casting article;   spreading a second layer of the powdered material on top of the first cross-sectional layer; and   melting the second layer to form a second cross-sectional layer of the casting article.   
     
     
         4 . The method as recited in  claim 1 , wherein a leaching path extends at least partially through the at least one of the circuit forming portions. 
     
     
         5 . The method as recited in  claim 1 , wherein the at least one of the circuit forming portions includes a first leg that includes the interior channel and a second leg that includes a second interior channel configured differently than the interior channel. 
     
     
         6 . The method as recited in  claim 1 , further comprising:
 moving a delivery platform in a first direction to position a powdered material relative to a build platform; and   moving a spreader in a second direction perpendicular to the first direction to deposit a layer of the powdered material on the build platform.   
     
     
         7 . The method as recited in  claim 6 , further comprising:
 melting the layer of powdered material to prepare a first layer.   
     
     
         8 . The method as recited in  claim 7 , further comprising:
 moving the build platform in a third direction opposite the first direction; and   depositing a second layer of powdered material on the build platform with the spreader.   
     
     
         9 . The method as recited in  claim 8 , further comprising
 melting the second layer of powdered material.   
     
     
         10 . The method as recited in  claim 1 , wherein the casting article is a core defining internal circuitry of a gas turbine engine part. 
     
     
         11 . The method as recited in  claim 10 , wherein the core provides an internal channel in the gas turbine engine part. 
     
     
         12 . The method as recited in  claim 11 , wherein the internal channel includes an engineering failure feature for enhancing core compressibility. 
     
     
         13 . The method as recited in  claim 12 , wherein the engineering failure feature includes a thinned portion including a first wall thickness of an outer shell body that is less than a second wall thickness of the outer shell body. 
     
     
         14 . The method as recited in  claim 12 , wherein the engineering failure feature includes one or more porous areas formed into an outer shell body that are less dense than other portions of the outer shell body. 
     
     
         15 . The method as recited in  claim 12 , further comprising, causing the engineering failure feature to deflect, crush, or collapse at a preferred location.