Abstract: A method for attaching a first component composed of a ceramic matrix composite (CMC) to a second component composed of a metallic substructure is provided. The first component comprises at least two slots formed within a body of the first component and a configured to accommodate a thickness of a continuous CMC strap. The ends of the CMC strap are inserted into respective slots in the first component and then inserted into corresponding slots in a second component. The ends are secured to the second component by a fastening means thus securing the first component to the second component.

Abstract: A method for attaching a first component composed of a ceramic matrix composite (CMC) to a second component composed of a metallic substructure is provided. The first component comprises at least two slots formed within a body of the first component and a configured to accommodate a thickness of a continuous CMC strap. The ends of the CMC strap are inserted into respective slots in the first component and then inserted into corresponding slots in a second component. The ends are secured to the second component by a fastening means thus securing the first component to the second component.

Abstract: There is provided a process for heat treating a component (30) having a first section (32) and a section shot peened section (34), the first section (32) and shot peened second section (34) formed from a nickel-based gamma prime strengthened superalloy. The process includes heating the first section (32) to at least a gamma prime solvus temperature thereof; and during the heating of the first section (32) to at least the gamma prime solvus temperature thereof, preventing the shot peened second section (34) from reaching a recrystallization temperature thereof.

Abstract: There is provided a process for heat treating a component (30) having a first section (32) and a section shot peened section (34), the first section (32) and shot peened second section (34) formed from a nickel-based gamma prime strengthened superalloy. The process includes heating the first section (32) to at least a gamma prime solvus temperature thereof; and during the heating of the first section (32) to at least the gamma prime solvus temperature thereof, preventing the shot peened second section (34) from reaching a recrystallization temperature thereof.

Abstract: A method (300) of using hot isostatic pressing to join metallic members that form a component in a gas turbine engine is disclosed. The method (300) may include applying (306) a surface treatment to the outer surfaces (14, 15, 16, 20, 22, 24) of first and second metallic members (12, 18) based on whether a mechanical or metallurgical joint for the component is desired. Additionally, the method (300) may include aligning (310) the outer surfaces (14, 15, 16, 20, 22, 24) of the first and second metallic members (12, 18) to create a sealed cavity, which encompasses the joint, between the first and second metallic members (12, 18). Once the outer surfaces (14, 15, 16, 20, 22, 24) are aligned, the method (300) may include subjecting (314) the members (12, 18) to hot isostatic pressing such that material from the first metallic member (12) flows into a recess (26) within the second metallic member (18) so as to join the first and second metallic members (12, 18) to form a consolidated component (10).

Abstract: 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.

Abstract: An airfoil (30) for a gas turbine (10) wherein the airfoil (30) includes an outer wall (32) having leading (34) and trailing (36) edges and convex (40) and concave (38) surfaces and wherein the outer wall (32) forms an internal cavity (52). The airfoil (30) includes at least one inner layer (42) located within the cavity (52), wherein the inner layer (42) has a shape that corresponds to the shape of the outer wall (32). The airfoil (30) also includes a leading edge insert (58) located adjacent the leading edge (34) of the outer wall (32). Further, the airfoil (30) includes a trailing edge insert (60) located adjacent the trailing edge (36) of the outer wall (32) wherein the at least one inner layer (42) is bonded to an inside surface (56) of the outer wall (32) to encapsulate the leading (58) and trailing (60) edge inserts.

Abstract: An interlocking modular airfoil for a turbine. The airfoil includes at least one support column extending from a lower plate and at least one first filament having at least one first side aperture that receives the support column in a first transverse direction. The airfoil also includes at least one second filament having at least one second side aperture that receives the support column in a second transverse direction, wherein the second filament includes a flange for covering the first side aperture. In addition, the airfoil includes a cooling channel extending through the support column, wherein the support column includes apertures for emitting a cooling fluid transmitted via the cooling channel for cooling the first and second filaments. Further, the airfoil includes an upper plate located on top of the first and second filaments for maintaining the first and second filaments under compression.

Abstract: An additive manufacturing apparatus (10) including: a container (12) configured to bound a bed of powdered metal material; a fluidization arrangement (18) configured to fluidize the bed of powered material; an articulation mechanism (40) disposed within the container and configured to support and to rotate a component (38) about at least one horizontal axis; and an energy beam (34) configured to selectively scan portions (36) of a surface of the bed of powdered metal material to melt or sinter the selectively scanned portions onto the component.

Abstract: A method of manufacturing an assembly (10), including: positioning a first component (12) and a second component (14) in a desired positional relationship with each other; and building-up a locking component (16) by depositing layer after layer of material onto a surface (24, 26) of the assembly until a completed locking component is formed in-situ that holds the first component and the second component in the desired positional relationship.

Abstract: A hybrid die cast system (10) having an inner liner insert (12) that enables the configuration of a component (18) produced by the system (10) to be easily changed by changing the inner liner insert (12) without having to rework the die housing (16) is disclosed. Because the inner liner insert (12) only need be removed and replaced to change the configuration of an outer surface (18) of a component (18) produced by the system (10), the cost savings is significant in contrast with conventional systems in which the die would have to be reworked. The system (10) may also include a cooling system (20) for controlling the casting process by controlling the rate of solidification and the rate of cooling of the casting. Local heating and cooling may be used to control the microstructure, enhance mold fill and reduce casting defects such as porosity.

Abstract: A component (34A, 34B, 34C) has a core formed of a stack (25, 36) of sheets (20) of material with cutouts (22A) aligned to form passages (38) in the core. An outer casing (29) spans the stack axially (51), brackets at least parts of opposed ends of the stack, and holds the sheets together in axial compression (46). Respective cooperating elements (30, 31) on the casing and the stack may register the casing with respect to the stack. Pins (24) in some sheets may engage holes (23) in adjacent sheets to register the sheets with each other. The casing may be segmented (28A, 28B, 28C). A hoop (66) may be compressed around the segmented casing. A gas turbine fuel injector may be formed of a stack (36) with an inlet element (44) compressed (46) onto the stack by the casing (29).

Abstract: A method (300) of using hot isostatic pressing to join metallic members that form a component in a gas turbine engine is disclosed. The method (300) may include applying (306) a surface treatment to the outer surfaces (14, 15, 16, 20, 22,24) of first and second metallic members (12, 18) based on whether a mechanical or metallurgical joint for the component is desired. Additionally, the method (300) may include aligning (310) the outer surfaces (14, 15, 16, 20, 22, 24) of the first and second metallic members (12, 18) to create a sealed cavity, which encompasses the joint, between the first and second metallic members(12, 18). Once the outer surfaces (14, 15, 16, 20, 22, 24) are aligned, the method (300) may include subjecting (314) the members (12, 18) to hot isostatic pressing such that material from the first metallic member (12) flows into a recess (26) within the second metallic member (18) so as to join the first and second metallic members (12, 18) to form a consolidated component (10).

Abstract: A pre-weld heat treatment of the nickel based superalloy including heating a nickel based superalloy (e.g., IN939) casting to 2120° F. at a rate of 2° F. per minute, and then soaking the casing for one hour at 2120° F. The casting is then cooled in stages including slowly cooling the casting at a rate of 1° F. per minute to about 1900° F. and holding at that temperature for about 10 minutes. Then the casting is further slowly cooled at a rate of 1° F. per minute to about 1800° F. and holding at that temperature for about 10 minutes, and further slowly cooled to a temperature range of 1650° F. to 1450° F., and then fast cooled to room temperature. The pre-weld heat treatment may optionally include a step of heating the casting to about 1850° F. at a rate of 50° F. per minute before slowly heating to 2120° F.

Abstract: 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.

Abstract: An additive manufacturing apparatus (10) including: a container (12) configured to bound a bed of powdered metal material; a fluidization arrangement (18) configured to fluidize the bed of powered material; an articulation mechanism (40) disposed within the container and configured to support and to rotate a component (38) about at least one horizontal axis; and an energy beam (34) configured to selectively scan portions (36) of a surface of the bed of powdered metal material to melt or sinter the selectively scanned portions onto the component.

Abstract: A component (34A, 34B, 34C) has a core formed of a stack (25, 36) of sheets (20) of material with cutouts (22A) aligned to form passages (38) in the core. An outer casing (29) spans the stack axially (51), brackets at least parts of opposed ends of the stack, and holds the sheets together in axial compression (46). Respective cooperating elements (30, 31) on the casing and the stack may register the casing with respect to the stack. Pins (24) in some sheets may engage holes (23) in adjacent sheets to register the sheets with each other. The casing may be segmented (28A, 28B, 28C). A hoop (66) may be compressed around the segmented casing. A gas turbine fuel injector may be formed of a stack (36) with an inlet element (44) compressed (46) onto the stack by the casing (29).

Abstract: A method and an apparatus for controlling a grain size of a component generated using an additive manufacturing process. Construct a first fused layer of the component by fusing a plurality of layers of a fusible material, wherein the first fused layer has a thickness T1. Thereafter, introduce stress through the first fused layer of the component. The component is generated by repeating the aforementioned steps. Further, the component is heated to a temperature above a recrystallization start temperature (Rxst) to control the grain size of the component.

Abstract: In a method for repairing a machinery component, one or more defects are detected on the machinery component. At least one portion of the component is removed, wherein the at least one portion includes at least one of the one or more defects. One or more data points are determined for at least one slot, wherein the at least one slot is created by removing the at least one portion of the component. At least one repair coupon is generated from the one or more data points. The at least one repair coupon is attached with the at least one slot.

Abstract: A method of manufacturing an assembly (10), including: positioning a first component (12) and a second component (14) in a desired positional relationship with each other; and building-up a locking component (16) by depositing layer after layer of material onto a surface (24, 26) of the assembly until a completed locking component is formed in-situ that holds the first component and the second component in the desired positional relationship.