Abstract: A process includes agitating at least one core of a core alloy together with a braze binder to form at least one coated core comprising the at least one core coated with a first layer of the braze binder. The process also includes agitating the at least one coated core together with a powder composition comprising a first metal powder of a first alloy and a second metal powder of a second alloy to form a green preform having a first powder composition layer of the first alloy and the second alloy. The process further includes sintering the green preform to form at least one hybrid pre-sintered preform. A green preform includes a core, a first layer of a braze binder coated on the core, and a powder composition coated on the first layer. A hybrid pre-sintered preform includes a core and a first layer sintered to the core.

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: Manufactured articles, and methods of manufacturing enhanced surface smoothed components and articles. More particularly, surface smoothed components and articles, such as combustor components of turbine engines, having surface treatment conferring reduced roughness for enhanced performance and reduced wear related reduction in part life.

Abstract: A method of fabricating a component includes preparing at least a portion of a surface of the component and forming a pre-sintered preform hybrid hardface mixture comprising combining a predetermined portion of at least one hardfacing material with a predetermined portion of at least one brazing material. The method further includes forming a pre-sintered preform using additive manufacturing, the pre-sintered preform having a near-net shape and forming a sintered preform. The method further includes positioning the sintered preform on the component and fixedly coupling the sintered preform to at least a portion of the component via brazing.

Abstract: A thermally dissipative article and a method of forming a thermally dissipative article are disclosed. The thermally dissipative article includes a component, a porous material formed in a layer on the component. The method of forming a thermally dissipative article includes providing a metal powder mixture and a soluble particulate mixture which forms a porous coating upon sintering and immersion in a solvent to remove the soluble particulate.

Abstract: A method of forming a passive strain indicator on a preexisting component includes directly depositing a plurality of fiducial markers on a portion of the outer surface of the preexisting component, the fiducial markers including a material that is compatible with the material of the outer surface. A method of evaluating a component includes initially scanning a plurality of fiducial markers on a portion of an outer surface of the component, subjecting the component to at least one duty cycle, subsequently scanning the plurality of fiducial markers after the at least one duty cycle, measuring a displacement of the plurality of fiducial markers by comparing the subsequent scan to the initial scan, and determining a remaining usable life of the component by looking up in a database a predetermined value of the remaining usable life of the component corresponding to the measured displacement of the plurality of fiducial markers.

Abstract: Components are disclosed which include a first component section and a second component section joined to form a hollow structure defining a plenum having an interior surface, wherein the component sections each include mating ridges joined together along the length of the plenum, and a corrosion-resistant cladding layer including a corrosion-resistant material overlaying the interior surface of the plenum. In one embodiment, the component is a gas turbine combustor fuel manifold. A method of forming the components includes applying corrosion-resistant segments including a corrosion-resistant material to each of the surfaces of the component sections, and joining the component sections to form the component, wherein joining the component sections includes fusing the corrosion-resistant segments into the corrosion-resistant cladding layer, and joining the mating ridges of the component sections.

Abstract: A method of making a pre-sintered preform, including forming a pre-sintered preform by a binder jet additive manufacturing technique. The binder jet additive manufacturing technique includes depositing a first powder layer including a first powder and a second powder followed by depositing a first binder at a pre-determined location of the first powder layer. The binder jet additive manufacturing technique also includes depositing a second powder layer over at least a portion of the first powder layer followed by depositing a second binder at a pre-determined location of the second powder layer. At least a portion of the first binder and at least a portion of the second binder is cured forming a green part. The green part is then densified to form a pre-sintered preform near net shape component.

Abstract: A hybrid additive manufacturing method comprises building an additive structure on a pre-sintered preform base, wherein building the additive structure comprises iteratively fusing together a plurality of layers of additive material with at least a first layer of additive material joined to the pre-sintered preform base, and wherein the pre-sintered preform base comprises an initial shape. The hybrid additive manufacturing method further comprises modifying the initial shape of the pre-sintered preform base comprising the additive structure into a modified shape comprising the additive structure, and, joining the pre-sintered preform base in its modified shape to a component.

Abstract: A hybrid article is disclosed including a sintered coating disposed on and circumscribing the lateral surface of a core having a core material and a greater density than the sintered coating. The sintered coating includes more than about 95% up to about 99.5% of a first metallic particulate material including a first melting point, and from about 0.5% up to about 5% of a second metallic particulate material having a second melting point lower than the first melting point. A method for forming the hybrid article is disclosed including disposing the core in a die, introducing a slurry having the metallic particulate materials into a gap between the lateral surface and the die, and sintering the slurry. A method for welding a workpiece is disclosed including the hybrid article serving as a weld filler.

Abstract: A clad article is disclosed including an article and a cladding layer. The article includes a surface layer, at least one cavity disposed within the article below the surface layer, and at least one microcrack disposed in the surface layer. The surface layer includes an HTW alloy. The cladding layer is disposed on a surface of the surface layer, and is formed from a PSP brazed to the article. The cladding layer is disposed over the at least one microcrack. A method for forming the clad article is disclosed including disposing the PSP on the article and brazing the PSP to the article. Brazing the PSP to the article forms the cladding layer disposed on the article over the at least one microcrack.

Abstract: A hybrid preform component including a plurality of elongated metallic cores and a coating paste is provided. The coating paste envelops the plurality of elongated metallic cores. The coating paste includes a first material having a first melting point, a second material having a second melting point, and a binder. A method for treating a component is also provided. The method includes the step of mixing a second material, a first material, and a binder to make coating paste. The method further includes the step of coating the plurality of cores using the coating paste to form a coated rod assembly. The method further includes the step of compressing the coated rod assembly to envelop the coating paste to the plurality of cores and form a preform component having a near net shape. The method further includes the step of sintering the preform component to form a pre-sintered preform.

Abstract: A method for counteracting tensile stress in an article is disclosed, including heating the article and applying compressive stress to the article along a compressive stress vector, the compressive stress vector including a compressive stress vector component opposite in direction to a tensile stress vector of a thermally-induced tensile stress of the article. The compressive stress is applied by thermally-induced autogenous pressure by a fixture contacting the article. A fixture for counteracting tensile stress is disclosed, including a first compression member and a second compression member, and a position lock connecting the first compression member to the second compression member and reversibly fixing the first compression member relative to the second compression member. The first compression member and the second compression member include compressive surfaces having mating conformations for surfaces of an article. The position lock includes a material composition.

Abstract: A hybrid article is disclosed including a coating disposed on and circumscribing the lateral surface of a core having a core material. The coating includes about 35% to about 95% of a first metallic material having a first melting point, and about 5% to about 65% of a second metallic material having a second melting point lower than the first melting point. A method for forming the hybrid article is disclosed including disposing the core in a die, forming a gap between the lateral surface and the die, introducing a slurry having the metallic materials into the gap, and sintering the slurry, forming the coating. A method for closing an aperture of an article is disclosed including inserting the hybrid article into the aperture. Closing the aperture includes brazing the hybrid article to the article, welding the aperture with the hybrid article serving as weld filler, or a combination thereof.

Abstract: A method of making a preform and preform formed by the method. The method includes providing a first pre-preg ply including at least a first fiber and a first resin. The method also includes providing a second pre-preg ply including at least a second fiber and a second resin over at least a portion of the first pre-preg ply. Heat or electromagnetic radiation is used to at least partially cure the first and second resins to form a cured preform. Heat is applied to pyrolyze at least a portion of the resin of the cured preform to form a pyrolyzed preform. A mechanical stimulus including at least one of controlled drying, local explosions, or ultrasonic energy is applied to the pyrolyzed preform. The mechanically treated pyrolyzed preform is subsequently densified by melt infiltration to form a densified preform.

Abstract: A cooling article and method of forming a cooling article are provided. The cooling article includes a body portion separating an inner region and an outer region, an aperture in the body portion, the aperture fluidly connecting the inner region and the outer region, and a reinforcing feature extending at least partially along the body portion, the reinforcing feature being oriented with respect to a build direction. The method includes forming a body portion defining an inner region and an outer region, forming at least one reinforcing feature concurrently with the forming of the body portion, the at least one reinforcing feature extending at least partially along the body portion, and forming an aperture in the body portion, the aperture fluidly connecting the inner region to the outer region. The forming the body portion, forming the aperture, and forming the at least one reinforcing feature comprises additive manufacturing.

Abstract: The present disclosure is directed to a method for forming a passage in a composite component. The method includes forming a cavity in a fiber preform. The cavity forms a portion of the passage. The method also includes inserting a core into the cavity and placing one or more fiber plies onto the fiber preform to form a fiber preform assembly. The method further includes thermally processing the fiber preform assembly and densifying the fiber preform assembly to form the composite component. The method also includes removing the core from the composite component.

Abstract: A component having a hybrid coating system is provided. The component includes a substrate having a surface and a hybrid coating system including a sheet disposed on the surface and a skin. The sheet includes a plurality of interlocking members. The skin includes a plurality of features corresponding to the interlocking members. The skin is engaged to the sheet in an interlocking manner via the interlocking members and the features. A method for forming a component with a hybrid coating system is also disclosed.

Abstract: A method of fabricating a component having active cooling with film holes and other exposed holes is provided. The method includes the step of providing a component including at least one aperture disposed on a surface of the component and fluidly connected to at least one fluid flow passage, the at least one aperture comprising a floor extending from the at least one fluid flow passage to the surface of the component, and a ceiling facing the floor. The method further includes the step of applying a thermal barrier coating over at least a portion of a substrate. The method further includes the step of removing a portion of the thermal barrier coating covering the at least one aperture. The method further includes the step of forming with an additive manufacturing method one or both of a sharp-edged hood of the at least one aperture and at least one feature disposed on the floor.

Abstract: An alloy is disclosed, including, by weight, about 13% to about 17% chromium, about 16% to about 20% molybdenum, about 1.5% to about 4% silicon, about 0.7% to about 2% boron, about 0.9% to about 2% aluminum, about 23% to about 27% nickel, about 0.8% to about 1.2% tantalum, and a balance of cobalt. The alloy includes a reduced occurrence of molybdenum silicide Laves phase relative to T800. A welded article is disclosed, including an article and a weld filler deposit joined to the article. The weld filler deposit includes a weld filler material including the alloy. A welding process is disclosed, including applying the weld filler material to the article and forming the weld filler deposit.