Patent ID: 8727714

Claim:
A method of forming a multi-panel outer wall including an impingement cooling panel for components that are used under high thermally stressed conditions and having complex outer surface contours, comprising: providing a component to be incorporated in a machine and perform in an environment of high thermally stressed conditions and comprising an inner panel having an outer surface with an array of interconnecting ribs with a respective base disposed on the outer surface, said interconnecting ribs having a tapered cross-section such that a cross-sectional area at the base of the interconnecting ribs is larger than a cross-sectional area at an outer tip of the interconnecting ribs; positioning an intermediate panel over the inner panel to cover at least a portion of the outer surface and the interconnecting ribs of the inner panel; applying an external force under pressure across a surface area of the intermediate panel against the outer surface of the inner panel to contour the intermediate panel according to a geometric configuration formed by the interconnecting ribs, thereby forming cooling chambers between the outer surface and the interconnecting ribs of the inner panel and the intermediate panel; and, forming one or more holes in the intermediate panel and the inner panel to allow air flow into and out of the cooling chambers.