# US 10,307,817 B2 · Additively manufactured casting articles for manufacturing gas turbine engine parts > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,307,817 B2 - Document ID: US10307817B2 - Status: Granted - Kind: B2 - Application number: 14/870,443 - Filed: 2015-09-30 - Published: 2016-06-30 - Granted: 2019-06-04 - Earliest claimed: 2014-10-31 - Assignees: United Technologies Corporation - Applicants: United Technologies Corporation - Inventors: Thomas N. Slavens; Mark F. Zelesky; JinQuan Xu; Joel H. Wagner - Web page: https://patentgrep.com/patent/US10307817B2 ## CPC - B22C 9/24: for hollow articles - B22C 1/00: Compositions of refractory mould or core materials; Grain structures thereof (refractory materials in general C04B35/00); Chemical or physical features in the formation or manufacture of moulds - B22C 9/02: Sand moulds or like moulds for shaped castings - B22C 9/10: Cores; Manufacture or installation of cores {(breaker cores B22C9/084)} - B22C 9/106: {Vented or reinforced cores} - B22D 29/002: {by leaching, washing or dissolving} - B22F 5/009: {of turbine components other than turbine blades (of turbine blades B22F5/04)} - B22F 5/04: of turbine blades - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - F01D 5/18: Hollow blades, {i.e. blades with cooling or heating channels or cavities (structure of hollow blades in general F01D5/147)}; Heating, heat-insulating or cooling means on blades - B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] - B33Y 10/00: Processes of additive manufacturing - B33Y 80/00: Products made by additive manufacturing - F05D 2230/30: with deposition of material - Y02P 10/25: Process efficiency - B22C: FOUNDRY MOULDING (moulding refractory materials in general B28B) - B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract A casting article according to another exemplary aspect of the present disclosure includes, among other things, a circuit forming portion including an interior channel and an outer shell body that surrounds the interior channel. An engineered failure feature is formed in the outer shell body and is configured to increase compressibility of the casting article during a casting process. ## Claims ### Claim 1 A casting article, comprising: a circuit forming portion including an interior channel and an outer shell body that surrounds said interior channel; and at least one porous area formed in said outer shell body at a portion of said outer shell body surrounding said interior channel and having a first density that is less than a second density of a second portion of said outer shell body and configured to increase compressibility of the casting article during a casting process, wherein the at least one porous area is configured to deflect, crush, or collapse at a preferred location during solidification of a molten metal encapsulating the casting article. ### Claim 2 (depends on 1) The casting article as recited in claim 1, wherein said interior channel establishes a leaching path through said circuit forming portion. ### Claim 3 (depends on 1) The casting article as recited in claim 1, comprising a plurality of porous areas having said first density formed in said outer shell body. ### Claim 4 (depends on 1) The casting article as recited in claim 1, wherein the at least one porous area is formed in a rib forming wall of said outer shell body configured to form a rib. ### Claim 5 (depends on 4) The casting article as recited in claim 4, wherein said at least one porous area is configured to fail toward said interior channel. ### Claim 6 (depends on 1) The casting article as recited in claim 1, wherein said circuit forming portion comprises refractory metal. ### Claim 7 A casting article, comprising: a circuit forming portion including a plurality of interior channels establishing a leaching path through said circuit forming portion and an outer shell body that surrounds one of said plurality of interior channels; and a thinned portion formed in a rib forming wall of said outer shell body configured to form a rib between said plurality of channels at a portion of said outer shell body surrounding said one of said interior channels, said thinned portion having a reduced thickness compared to a second portion of said outer shell body and configured to deflect, crush, or collapse at a preferred location during solidification of a molten metal encapsulating the casting article. ### Claim 8 (depends on 7) The casting article as recited in claim 7, wherein said thinned portion is configured to deflect, crush, or collapse toward said one of said interior channels during solidification of a molten metal encapsulating the casting article. ### Claim 9 (depends on 7) The casting article as recited in claim 7, wherein said circuit forming portion comprises refractory metal. ### Claim 10 A casting article, comprising: a circuit forming portion including a plurality of interior channels establishing a leaching path through said circuit forming portion and an outer shell body that surrounds one of said plurality of interior channels; and at least one porous area formed in a rib forming wall of said outer shell body configured to form a rib between said plurality of channels at a portion of said outer shell body surrounding said one of said interior channels and having a first density that is less than a second density of a second portion of said outer shell body and configured to deflect, crush, or collapse at a preferred location during solidification of a molten metal encapsulating the casting article. ### Claim 11 (depends on 10) The casting article as recited in claim 10, wherein said at least one porous area is configured to deflect, crush, or collapse toward said one of said interior channels during solidification of a molten metal encapsulating the casting article. ### Claim 12 (depends on 11) The casting article as recited in claim 11, wherein said rib includes said molten metal. ### Claim 13 (depends on 10) The casting article as recited in claim 10, wherein said circuit forming portion comprises refractory metal.