Gas turbine engine airfoil impingement cooling

A method of manufacturing an airfoil comprising the steps of:

• depositing multiple layers of powdered metal onto one another;
• joining the layers to one another with reference to CAD data relating to a particular cross-section of an airfoil;
• and
• producing the airfoil with leading and trailing edges joined by spaced apart pressure and suction sides to provide an exterior airfoil surface, an exterior wall providing the exterior airfoil surface at the leading edge, an impingement wall integrally formed with the exterior wall to provide an impingement cavity between the exterior wall and the impingement wall, and multiple impingement holes provided in the impingement wall, the impingement holes spaced laterally across the impingement wall.

A method of manufacturing a core for an airfoil comprising the steps of:

• depositing multiple layers of powdered metal onto one another;
• joining the layers to one another with reference to CAD data relating to a particular cross-section of a core;
• and
• producing the core with a first structure corresponding to a cooling passage, a second structure corresponding to an impingement cavity and columns interconnecting the first and second structures, the columns corresponding to multiple impingement cooling holes, the first and second structures and the columns are integrally formed.