US Patent 10260352 Gas turbine blade with corrugated tip wall

A gas turbine engine blade (10), including a base portion (12) having a cast wall, and a tip portion (14) attached to the base portion and having a wall (60) formed by an additive manufacturing process. The tip portion wall may be formed to be solid and less than 2 mm in thickness, or it may be corrugated and be greater than 2 mm in thickness. Openings (80) defining the wall corrugations may be semi-circular, rectangular, trapezoidal, or elliptical in cross-sectional shape. The resulting blade has lower tip mass while retaining adequate mechanical properties. The tip portion may be formed to have a directionally solidified grain structure on a base portion having an equiaxed grain structure.