Components with multi-layered cooling features and methods of manufacture

A manufacturing method comprising:

• providing a substrate with an outer surface and at least one interior space and having one or more grooves formed in a portion of the substrate, wherein each groove extends at least partially along the substrate;
• applying one or more coatings on at least a portion of the substrate to define at least one distribution header in the substrate;
• forming one or more grooves in each of the one or more coatings, wherein each groove extends at least partially along the one or more coatings and in fluid communication with the at least one distribution header in the substrate;
• applying a cover coating on at least a portion of an outermost surface of the one or more coatings;
• and
• forming one or more cooling outlets in the cover coating and in fluid communication with the one or more grooves formed in the one or more coatings,
• wherein the substrate, the one or more coatings and the cover coating define a cooling network defined by one or more cooling flow channels having portions formed in the substrate and in the one or more coatings for cooling a component.

A component comprising

• a substrate comprising an outer surface and an inner surface, wherein the inner surface defines at least one interior space, the substrate including one or more grooves formed in a portion of the substrate, wherein each groove extends at least partially along the substrate and wherein one or more cooling supply inlets are formed through a base of a respective groove in the substrate, to connect the groove in fluid communication with an interior space;
• one or more coatings disposed on at least a portion of the substrate, wherein the one or more coatings define one or more grooves therein, wherein each groove extends at least partially along the outer surface of one of the one or more coatings;
• and
• a cover coating disposed over at least a portion of an outermost coating of the one or more coatings and wherein one or more cooling outlets are formed through the cover coating, to connect the one or more grooves in the one or more coatings to an exterior, wherein the substrate, the one or more coatings and the cover coating together define a cooling network for cooling comprised of one or more cooling flow channels for cooling the component.