Abstract:
Methods of manufacturing or repairing a turbine blade or vane are described. The airfoil portions of these turbine components are typically manufactured by casting in a ceramic mold, and a surface made up of the cast airfoil and at the least the ceramic core serves as a build surface for a subsequent process of additively manufacturing the tip portions. The build surface is created by removing a top portion of the airfoil and the core, or by placing an ultra-thin shim on top of the airfoil and the core. The overhang projected by the shim is subsequently removed. These methods are not limited to turbine engine applications, but can be applied to any metallic object that can benefit from casting and additive manufacturing processes. The present disclosure also relates to finished and intermediate products prepared by these methods.
Abstract:
Methods for creating a cast component, along with the resulting cast components, are provided. The method may include heating a mold having a cavity therein; supplying a first molten metal material into the cavity of the mold such that the first molten metal material is directed to a first portion of the cavity of the mold; supplying a second molten metal material into the cavity of the mold such that the second molten metal material is directed to a second portion of the cavity of the mold, wherein the first molten metal material is compositionally different than the second molten metal material; and thereafter, allowing the first molten metal material and the second molten metal material to form the cast component.
Abstract:
A method and apparatus for minimizing engine weight for a turbine engine by utilizing one or more discrete protuberances disposed on an engine component wall. The wall can have a nominal thickness to decrease engine weight while the protuberances can provide increased discrete thicknesses for providing one or more cooling holes. The increased thickness at the protuberances provides for an increased thickness to provide sufficient length to increase cooling hole effectiveness.
Abstract:
The present disclosure generally relates to casting molds including a casting shell surrounding at least a portion of a casting core comprising a first metal component and a hot isostactic pressed second metal component around the first metal component. In one aspect, the first metal component may have a lower melting point than the second metal component. In another aspect, the second metal component may retain some metal powder grain structure.
Abstract:
A method of fabricating an object is provided. The method includes depositing a first material between second material such that the second material is at opposite sides of the first material, the first material forming a metal, ceramic, or metal-ceramic. The second material is selectively removable from the first material to reveal sidewalls of the first material so that the first material has a more uniform vertical profile than would be the case if the first material was deposited without the second material.
Abstract:
A method and apparatus for minimizing engine weight for a turbine engine by utilizing one or more discrete protuberances disposed on an engine component wall. The wall can have a nominal thickness to decrease engine weight while the protuberances can provide increased discrete thicknesses for providing one or more cooling holes. The increased thickness at the protuberances provides for an increased thickness to provide sufficient length to increase cooling hole effectiveness.
Abstract:
Apparatus and methods for direct writing of single crystal super alloys and metals are provided. In one method, a substrate is heated to a pretermined temperature below its melting point, and a laser is used to form a melt pool on a surface of a substrate. The substrate is positioned on a base plate, and the laser and the base plate are movable relative to each other, with the laser being used for direct metal deposition and the substrate is heated to a temperature below its melting point. A superalloy powder is introduced to the melt pool, and the temperature of the melt pool is controlled to maintain a predetermined thermal gradient on a solid and liquid interface of the melt pool so as to form a single crystal deposit on the substrate.
Abstract:
A method and apparatus for minimizing engine weight for a turbine engine by utilizing one or more discrete protuberances disposed on an engine component wall. The wall can have a nominal thickness to decrease engine weight while the protuberances can provide increased discrete thicknesses for providing one or more cooling holes. The increased thickness at the protuberances provides for an increased thickness to provide sufficient length to increase cooling hole effectiveness.
Abstract:
A nickel-based superalloy is provided, which includes: 5.6 wt % to 6.6 wt % aluminum; 6.0 wt % to 9.0 wt % tantalum; 4.0 wt % to 7.0 wt % chromium; 4.0 wt % to 7.0 wt % tungsten; 0.5 wt % to 2.5 wt % molybdenum; 1.5 wt % to 5.5 wt % rhenium; 7.0 wt % to 13.0 wt % cobalt; 0.1 wt % to 0.7 wt % hafnium; 0.001 wt % to 0.005 wt % carbon; 0.002 wt % to 0.05 wt % boron; up to 0.1 wt % yttrium; and a balance of nickel and incidental impurities, wherein the composition exhibits a rupture life that is greater than 80 hours at 1093.3° C. and 20 ksi and an oxidation resistance of less than 25.4 μm surface loss at 1176.7° C. after a 400 hour Mach I test. Components are also provided formed from such a nickel-based superalloy.
Abstract:
An engine component for a turbine engine, the engine component comprising a wall bounding an interior; a panel portion defining a portion of the wall, the panel portion comprising: an outer wall; an inner wall spaced from the outer wall to define a wall gap; and a structural segment formed within the wall gap comprising at least one structural element. The apparatus formed from a method including calculating a factor and adjusting a variable until the factor is between a given range.