Abstract: A method of forming a component includes mixing a powdered base material and a binder to define a mixture, forming the mixture into a desired shape without melting the base material, removing the binder from the desired shape to define a skeleton, the volume of the skeleton being between 80 percent and 95 percent base material, and infiltrating the skeleton with a melting point depressant material to define a finished component, the finished component having less than one percent porosity by volume.

Abstract: A blade for a gas turbine includes a removed portion space, and further includes an airfoil portion defining the removed portion space, the airfoil portion formed from a base material, and a replacement component formed to fill the removed portion space. The replacement component is formed from a material that includes 50%-80% base material, 0%-30% braze material, and 0%-8% aluminum. A braze joint is formed between the airfoil portion and the replacement component to attach the replacement component to the airfoil portion and fill the removed portion space.

Abstract: A support housing for use in distributing fuel in a gas turbine engine includes a main body defining an inlet aperture, a plurality of outlet apertures, and a substantially planar mounting surface. A first fuel channel has a wall that defines a first flow space and a support member extends across the first flow space and has a long axis oriented at an oblique angle with respect to the mounting surface.

Abstract: A blade for a gas turbine includes a removed portion space, and further includes an airfoil portion defining the removed portion space, the airfoil portion formed from a base material, and a replacement component formed to fill the removed portion space. The replacement component is formed from a material that includes 50%-80% base material, 0%-30% braze material, and 0%-8% aluminum. A braze joint is formed between the airfoil portion and the replacement component to attach the replacement component to the airfoil portion and fill the removed portion space.

Abstract: A method of forming a component includes mixing a powdered base material and a binder to define a mixture, forming the mixture into a desired shape without melting the base material, removing the binder from the desired shape to define a skeleton, the volume of the skeleton being between 80 percent and 95 percent base material, and infiltrating the skeleton with a melting point depressant material to define a finished component, the finished component having less than one percent porosity by volume.

Abstract: A method of additive manufacturing a component. The method includes selecting powder characterization, depositing powder materials, inspecting the powder materials, selecting process and laser parameters for laser processing, laser processing the powder materials, performing layer cleanup, determining stress state and relieving, additionally inspecting the laser processed powder materials, and repeating steps until a buildup of the component is complete.

Abstract: A computer-implemented method for assessing material microstructure of a machine component involves obtaining a raw image of a section of the component captured via a microscope. The method further includes pre-processing the raw image to generate a ternary image defined by pixel data including three levels of intensities. The method further includes identifying, from the ternary image, phase boundaries delineating at a phase in a primary constituent material of the component. The method further includes determining a volume associated with the phase based on the identified phase boundaries. The proposed method may be utilized, for example, as an automated tool for assessing material degradation and for quality control of gas turbine engine components.

Abstract: A turbine blade includes a platform with an internal cavity formed therein and an airfoil extending radially from the platform. The turbine blade includes a first portion made from ceramic matrix composite materials and a second portion made from superalloy materials. The first and second portions are selectively connected to each other via a spur and include an internal cooling circuit extending across both the first and second portions for circulating coolant therethrough. At least one supply passage extends between the internal cooling circuit and the internal platform cavity and includes an array of pin fins and turbulators for diverting coolant to the internal platform cavity.

Abstract: Materials and a process for forming a protective oxide coating. The high temperature coating system (108) includes at least a thermal barrier coating layer (104) and a thermally stable, deposit resistant protective layer (106) on the thermal barrier coating layer (104).

Abstract: A computer-implemented method for assessing material microstructure of a machine component involves obtaining a raw image of a section of the component captured via a microscope. The method further includes pre-processing the raw image to generate a ternary image defined by pixel data including three levels of intensities. The method further includes identifying, from the ternary image, phase boundaries delineating at a phase in a primary constituent material of the component. The method further includes determining a volume associated with the phase based on the identified phase boundaries. The proposed method may be utilized, for example, as an automated tool for assessing material degradation and for quality control of gas turbine engine components.

Abstract: A support housing for use in distributing fuel in a gas turbine engine includes a main body defining an inlet aperture, a plurality of outlet apertures, and a substantially planar mounting surface. A first fuel channel has a wall that defines a first flow space and a support member extends across the first flow space and has a long axis oriented at an oblique angle with respect to the mounting surface.

Abstract: A turbine blade having an airfoil portion includes a first ceramic matrix composite (CMC) component having a first outer surface and a second ceramic matrix composite (CMC) component having a second outer surface. The second CMC component is positioned adjacent the first CMC component such that the first outer surface and the second outer surface align with one another and at least partially define the airfoil portion. A ceramic bead is at least partially formed at an interface between the first CMC component and the second CMC component. The formation of the bead melts a portion of the first CMC component and the second CMC component, such that the ceramic bead, the first CMC component, and the second CMC component become a single contiguous component and the bead fixedly attaches the first CMC component and the second CMC component.

Abstract: A turbine blade having an airfoil portion includes a first ceramic matrix composite (CMC) component having a first outer surface and a second ceramic matrix composite (CMC) component having a second outer surface. The second CMC component is positioned adjacent the first CMC component such that the first outer surface and the second outer surface align with one another and at least partially define the airfoil portion. A ceramic bead is at least partially formed at an interface between the first CMC component and the second CMC component. The formation of the bead melts a portion of the first CMC component and the second CMC component, such that the ceramic bead, the first CMC component, and the second CMC component become a single contiguous component and the bead fixedly attaches the first CMC component and the second CMC component.

Abstract: 3D printed thermal management devices and corresponding methods of manufacturing are described herein. A thermal management device includes a single contiguous component. The single contiguous component includes a body, a plurality of first fins extending away from the body and a plurality of second fins extending away from the body. A surface area of each first fin of the plurality of first fins is different than a surface area of each second fin of the plurality of second fins. A fin density of the plurality of first fins is different than a fin density of the plurality of second fins.

Abstract: A method of additive manufacturing a component. The method includes selecting powder characterization, depositing powder materials, inspecting the powder materials, selecting process and laser parameters for laser processing, laser processing the powder materials, performing layer cleanup, determining stress state and relieving, additionally inspecting the laser processed powder materials, and repeating steps until a buildup of the component is complete.

Abstract: Materials and a process for forming a protective oxide coating. The high temperature coating system (108) includes at least a thermal barrier coating layer (104) and a thermally stable, deposit resistant protective layer (106) on the thermal barrier coating layer (104).

Abstract: A turbine blade includes a platform with an internal cavity formed therein and an airfoil extending radially from the platform. The turbine blade includes a first portion made from ceramic matrix composite materials and a second portion made from superalloy materials. The first and second portions are selectively connected to each other via a spur and include an internal cooling circuit extending across both the first and second portions for circulating coolant therethrough. At least one supply passage extends between the internal cooling circuit and the internal platform cavity and includes an array of pin fins and turbulators for diverting coolant to the internal platform cavity.

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: A non-destructive method for condition assessment of a turbine component is provided. The method includes providing a laser generating a light pulse that heats the turbine component. An infrared image is then captured of the heated turbine component. An analysis of the turbine component for a particular characteristic of the turbine component may then be done. A system for the non-destructive condition assessment of a turbine component is also provided.

Abstract: A blackbody material application system for a turbine. The system includes a blackbody material supply and a moveable hose connected to the blackbody material supply wherein the hose sprays blackbody material onto a selected area within the turbine. The system also includes a rotatable bracket that holds the hose, wherein rotation of the bracket moves the hose toward the selected area within the turbine to enable application of the blackbody material onto the selected area. In addition, the system includes a motor for rotating the bracket and a moveable arm that holds the bracket wherein the bracket is inserted through an opening in the turbine and movement of the arm enables positioning of the bracket and hose in relative close proximity to the selected area suitable for spraying blackbody material onto the selected area.