Abstract: An embodiment of an independent cooling circuit for selectively delivering cooling fluid to a component of a gas turbine system includes: at least one coolant feed channel fluidly coupled to a supply of cooling fluid; and an interconnected circuit of cooling channels, including: an interconnected circuit of cooling channels embedded within an exterior wall of the component; an impingement plate; and a plurality of feed tubes connecting the impingement plate to the exterior wall of the component and fluidly coupling a supply of cooling fluid to the interconnected circuit of cooling channels; wherein the cooling fluid flows through the plurality of feed tubes into the interconnected circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels.

Abstract: An article includes a substrate and a structure of additive manufacturing material of predetermined thickness attached to the substrate, the structure of additive manufacturing material formed by providing a metal alloy powder, forming an initial layer having a preselected thickness and a preselected shape including at least one aperture, with the metal alloy powder, sequentially forming an additional layer with the metal alloy powder over the initial layer, each of additional layers having an additional preselected thickness and an additional preselected shape including an aperture corresponding to the aperture in the initial layer, and joining each of the additional layers to the initial layer or any previously joined additional layers, forming a structure having a predetermined thickness and shape, and an aperture having a predetermined profile. The article includes a passageway through the structure including the aperture and a corresponding metering hole.

Abstract: An article includes a substrate and a structure including direct metal laser melted material of predetermined thickness attached to the substrate, the structure formed by providing and depositing a metal alloy powder to form an initial layer having a preselected thickness and shape including at least one aperture, melting the metal alloy powder with a focused energy source, transforming the powder layer to a sheet of metal alloy, sequentially depositing an additional layer of the metal alloy powder over the sheet of metal alloy, the additional preselected shape including an aperture corresponding to the aperture in the initial layer, and melting each additional layer of the metal alloy powder with the focused energy source, increasing the thickness of the sheet and forming at least one aperture having a predetermined profile, the article further including a passageway through the structure including the aperture and a corresponding metering hole.

Abstract: Hybrid welding methods include directing a laser beam from a laser onto a first component that is vertically offset from a second component, and, directing a weld arc from an arc welder onto a weld joint between the first component and the second component to weld the first and second components together.

Abstract: A process includes forming a printed article having an external surface and at least one microfeature with an internal surface by additive manufacture, coating the external surface and the internal surface of the printed article with a metallic microlayer to form a coated article, and densifying the coated article to form a component. After formation, the printed article has a porosity such that the printed article is not at full density. A densified component includes a printed article having an external surface and at least one microfeature with an internal surface and a metallic microlayer coating the external surface and the internal surface of the printed article. The printed article is formed by additive manufacture.

Abstract: A method for inspection of additive manufactured parts and monitoring operational performance of an additive manufacturing apparatus is provided. The method includes a step of obtaining, in real-time during an additively manufactured build process, a backscatter x-ray scan of an area of a build platform. The build platform is configured for supporting at least one part during the build process. An evaluating step evaluates, by a processor, the backscatter x-ray scan. A determining step determines, based on the evaluating, whether an operational flaw with the additive manufacturing apparatus has occurred or a defect in the at least one part has occurred. A backscatter x-ray system has an emitter that emits x-rays and a detector that receives backscattered x-rays. The emitter and detector are located on a movable support located above the build platform, and the movable support raises and lowers the emitter and detector with respect to the build platform.

Abstract: A multi-piece part includes multiple pieces fabricated via different types of fabrication processes, wherein the multiple parts are configured to be coupled to one another to form the assembly. At least one of the multiple parts is fabricated via an additive manufacturing method. The multi-piece part also includes a holder assembly that couples and holds together the multiple pieces of the multi-piece part, wherein the holder assembly comprises a reversible, mechanical-type coupling.

Abstract: A method of protecting a hole in a component during a coating process is disclosed. The method includes: placing a plug in the hole, the plug including a water insoluble core and a water soluble layer surrounding at least a portion of an outer surface of the metal core. A coating is applied over the plug and at least a portion of the component. The component is immersed in water to dissolve the water soluble layer, allowing removal of the water insoluble core. Removal of the coating from over the hole and the water insoluble core from within the hole may follow.

Abstract: Systems and methods for infiltrating porous ceramic matrix composite (CMC) preforms to form CMC articles are disclosed. One method may include positioning the porous CMC preform in an opening of a die set for an infiltration system, and flowing a molten densifier over the porous CMC preform in a first flow direction to infiltrate a plurality of voids formed between each of a plurality of ply stacks of the CMC preform. The method may also include flowing the molten densifier over the porous CMC preform in a second flow direction, distinct from the first flow direction, to infiltrate the plurality of voids formed between each of the plurality of ply stacks of the CMC preform. The second flow direction may be substantially parallel to a predetermined, unidirectional material orientation of at least one ply stack of the plurality of ply stacks of the CMC preform.

Abstract: A multi-piece part includes multiple pieces fabricated via different types of fabrication processes, wherein the multiple parts are configured to be coupled to one another to form the assembly. At least one of the multiple parts is fabricated via an additive manufacturing method. The multi-piece part also includes a holder assembly that couples and holds together the multiple pieces of the multi-piece part, wherein the holder assembly comprises a reversible, mechanical-type coupling.

Abstract: An aft frame for a duct of a combustor includes a rail or radial projection that extends circumferentially around the aft frame and that defines an outer surface of the aft frame. A preformed cover plate having an inner surface is attached to the outer surface of the aft frame. A plurality of micro-cooling channels is formed within at least one of the inner surface of the preformed cover plate and the outer surface of the aft frame. The preformed cover plate extends across the plurality of micro-cooling channels.

Abstract: A nozzle has a main body having an input side and an output side, a central region and two opposing end regions. A plurality of linearly arranged apertures extend from the input side to the output side, and each of the apertures has a respective opening. At least one opening in the central region is smaller than at least one opening in the end regions.

Abstract: Various embodiments include methods for densifying a melt infiltrated ceramic matrix composite (CMC) article, and a densified melt infiltrated CMC article formed thereby. Particular embodiments include a method including: providing a porous CMC preform within a first region of a casting apparatus; providing a molten densifier within a pressure head area of a second region of the casting apparatus, the first and second regions being operably connected and the molten densifier including at least one source of silicon; and applying a first pressure to the molten densifier within the pressure head, thereby infiltrating voids within the porous CMC preform with the molten densifier and forming a densified melt infiltrated CMC article.

Abstract: At least one turbine component for a gas turbine includes a base component formed by casting and an article. The base component includes a platform. The article on the upper surface of the platform is formed by additive manufacturing. The article has a proximal face sized and shaped to cover at least a portion of the upper surface of the platform of the turbine component and a contoured distal face opposite the proximal face. The contoured distal face has a contour surface serving as at least a portion of a hot gas path surface of the turbine component. The contour surface is arranged and disposed to provide a controlled flow pattern of a working fluid across the contour surface based on a clock mounting location of the turbine component in a turbine.

Abstract: A method of welding a component and a treated component are provided. The method comprises an initial heat-treating of the component comprising a substrate. The method further comprises removing a portion of the substrate to form a treatment region comprising an exposed surface. The method further comprises buttering the exposed surface with a first filler additive to form a weld metal adjacent to the fusion line comprising an easy-to-weld alloy. The method further comprises welding the component with the easy-to-weld alloy and a second filler additive. The first filler additive comprises a sufficient amount of each of Co, Cr, Mo, Fe, Al, Ti, Mn, C and Ni to form the easy-to-weld alloy, when welded with the hard-to-weld base alloy.

Abstract: An effusion cooling element for the surface of a hot gas path (HGP) component is disclosed. The effusion cooling element includes a coolant swirling chamber embedded within the body of the HGP component. A coolant delivery passage is in the body and configured to deliver a coolant to the coolant swirling chamber. The coolant swirling chamber imparts a centrifugal force to the coolant. An effusion opening is in the HGP surface and in fluid communication with the coolant swirling chamber, the effusion opening having a smaller width than the coolant swirling chamber. The coolant exits the effusion opening over substantially all of 360° about the effusion opening, creating a coolant film on the HGP surface.

Abstract: A method of additively manufacturing an article includes forming a first portion of the article by three-dimensional printing of a plurality of first layers from a first powder material cut having a first average particle size corresponding to a first feature resolution. The first layers have a first average layer thickness. The method also includes forming a second portion of the article by three-dimensional printing of a plurality of second layers from a second powder material cut having a second average particle size corresponding to a second feature resolution less than the first feature resolution. The second portion includes at least one feature. The second layers have a second average layer thickness less than the first average layer thickness. A three-dimensional printing system and an article formed from a powder material by three-dimensional printing are also disclosed.

Abstract: An article, a component, and a method of making a component are provided. The article includes a contoured proximal face and a contoured distal face. The contoured proximal face is arranged and disposed to substantially mirror a contour of an end wall of a component. The component includes a first end wall, a second end wall, and an article including a contoured proximal face secured to at least one of the first end wall and the second end wall. The method of making a component includes forming an article having a proximal face and a distal face, contouring the proximal face of the article to form a contoured proximal face that substantially mirrors a contour of a first end wall or a second end wall of the component, and securing the contoured proximal face of the article to one of the first end wall and the second end wall.

Abstract: A method of controlling an extent of a thermal barrier coating (TBC) sheet spall and a hot gas path (HGP) component are disclosed. The method provides an HGP component having a body with an exterior surface. Controlling the extent of the TBC sheet spall includes forming a TBC over a selected portion of the exterior surface of the body. The TBC includes a plurality of segments in a cellular pattern. Each segment is defined by one or more slots in the TBC, and each segment has a predefined area such that the extent of the TBC sheet spall is limited by the predefined area of each of the plurality of segments that constitute the TBC sheet spall.