Bi-casting a platform (50) onto an end portion (42) of a turbine airfoil (31) after forming a coating of a fugitive material (56) on the end portion. After bi-casting the platform, the coating is dissolved and removed to relieve differential thermal shrinkage stress between the airfoil and platform. The thickness of the coating is varied around the end portion in proportion to varying amounts of local differential process shrinkage. The coating may be sprayed (76A, 76B) onto the end portion in opposite directions parallel to a chord line (41) of the airfoil or parallel to a mid-platform length (80) of the platform to form respective layers tapering in thickness from the leading (32) and trailing (34) edges along the suction side (36) of the airfoil.
STATEMENT REGARDING FEDERALLY SPONSORED DEVELOPMENT
Development for this invention was supported in part by Contract No. DE-FC26-05NT42644 awarded by the United States Department of Energy. Accordingly, the United States Government may have certain rights in this invention.