Method of manufacturing an air cooled vane with film cooling pocket construction

The method of manufacturing an air cooled stator vane for a gas turbine engine including the steps of:

• casting a first half of an outer shell shaped in an airfoil with an outer curvature defining a leading edge, a trailing edge and a suction surface;
• forming in the step of casting the first half a plurality of spaced pockets in the outer shell in rows extending over the suction surface of the shell and forming slots with a slot being located at the end of each pocket and passages in the outer shell with each passage for each pocket extending in the direction of the leading edge from the trailing edge connecting with each of the slots;
• forming in the step of casting the first half a mating face at the leading edge and a mating face at the trailing edge;
• casting a second half of the outer shell shaped in an airfoil complementing the first half for forming the stator vane with an outer curvature defining a leading edge, a trailing edge and a pressure surface;
• forming in the step of casting the second half a plurality of pockets in the outer shell in rows extending over the pressure surface and forming slots with a slot being located at the end of each pocket and passages in the outer shell with each passage for each pocket extending in the direction of the leading edge from the trailing edge connecting with each slot;
• forming in the step of casting the second half a mating surface at the leading edge and a mating surface at the trailing edge;
• machining apertures through the cast outer shell from the interior of the outer shell so that each aperture is formed in a portion of the outer shell and extends from the interior of the outer shell to the pocket at a point remote from the slot;
• and
• joining said halves of airfoil shaped outer shells at the respective mating surfaces.