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 nickel-based superalloy composition including by weight percent: Cobalt 7.5; Chromium 9.75; Aluminum 5.45; Titanium 1.0; Niobium 3.5; Tungsten 6.0; Molybdenum 1.5; Carbon 0.08; Hafnium 0.15; Boron 0.01; and Nickel 65.0; and incidental impurities.

Abstract: A method for repairing a part and the resulting is disclosed. The method includes positioning a plug having an inner braze element coupled thereto into a cavity defined by an internal surface of a component. The cavity has a circular cross-section at the external surface of the component. The plug completely fills the circular cross-section and the inner braze element is within the cavity. A braze paste is positioned at least partially around the plug at the external surface. The component is positioned such that the inner braze element is above the plug. The component is subjected to a thermal cycle to melt the inner braze element around the plug, completely sealing the cavity by forming a metallurgical bond with the plug and the internal surface of the component. During the thermal cycle the braze paste is melted to form a metallurgical bond with the plug and external surface.

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: 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 closure element for an internal passage in a component, and a related method and turbine blade or nozzle are disclosed. The closure element includes a spherical body made of a first superalloy, and a plurality of extensions extending from a surface of the spherical body. The plurality of extensions made of the same, similar or different material other than the first superalloy. Subjecting the component to at least one thermal cycle causes a braze material to form a metallurgical bond with the spherical body, the plurality of extensions and the passage wall to seal the internal passage.

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: 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 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 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 thermal management article is disclosed including a substrate and a first coating disposed on the substrate. The first coating includes a first coating surface and at least one passageway disposed between the substrate and the first coating surface. The at least one passageway defines at least one fluid pathway. A method for forming a thermal management article is disclosed including attaching at least one passageway to a substrate. The at least one passageway includes a passageway wall having a wall thickness and defines at least one fluid pathway. A first coating is applied to the substrate and the passageway wall, forming a first coating surface. The at least one passageway is disposed between the substrate and the first coating surface.

Abstract: A system includes a gas turbine component having a recessed portion with a recessed surface in a hard-to-weld (HTW) material. The system includes a plate disposed over the recessed portion. The plate has an easy-to-weld (ETW) material. The plate has an outer surface and an inner surface, and the inner surface faces the recessed portion. The system includes a braze material disposed within the recessed portion between the recessed surface and the inner surface of the plate. The braze material is configured to bond the recessed surface of the recessed portion with the inner surface of the plate when the braze material is heated to a brazing temperature. The system includes a filler material disposed on the outer surface of the plate disposed over the recessed portion. Application of the filler material to the outer surface of the plate is configured to heat the braze material to the brazing temperature.

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 includes heating a brazing material in a braze chamber of a first component to a braze temperature to melt the brazing material. The brazing material flows from the braze chamber, through at least one internal channel of the first component, and into a braze gap between the first component and a second component to braze the first component to the second component. A brazed article includes a first component having a braze chamber and at least one internal channel extending from the braze chamber to an external surface, a second component having at least one braze surface separated from the external surface of the first component by a braze gap, and a braze material in the braze gap. A braze assembly includes a first component, a second component, and a brazing material in the braze chamber.

Abstract: A blade for a turbomachine, a tip for a blade of a turbomachine and a related method are disclosed. The blade may include a tip body having a shape at least partially configured for coupling to an airfoil body of the blade; at least one coolant passage in the tip body configured for fluid communication with at least one coolant passage in the airfoil body; and a retention member extending from the tip body for coupling to a tip retention member seat in the airfoil body. The tip can be replaced, allowing for changes in the coolant passages in the tip of a blade.

Abstract: A nozzle or blade for a turbomachine includes an airfoil body including at least one first coolant passage, and an edge opening in a leading edge or a trailing edge of the airfoil body. The edge opening has an edge coupon retention member seat in or on an inner surface of the airfoil body. An edge coupon has a shape at least partially configured for coupling to the edge opening in the airfoil body. The edge coupon includes an edge coupon body, at least one second coolant passage in the edge coupon body configured for fluid communication with the at least one first coolant passage in the airfoil body, and a retention member extending from the edge coupon body for coupling to the edge coupon retention member seat in the airfoil body.

Abstract: A composition of matter includes from about 16 to about 20 wt % chromium, greater than 6 to about 10 wt % aluminum, from about 2 to about 10 wt % iron, less than about 0.04 wt % yttrium, less than about 12 wt % cobalt, less than about 1.0 wt % manganese, less than about 1.0 wt % molybdenum, less than about 1.0 wt % silicon, less than about 0.25 wt % carbon, about 0.03 wt % boron, less than about 1.0 wt % tungsten, less than about 1.0 wt % tantalum, about 0.5 wt % titanium, about 0.5 wt % hafnium, about 0.5 wt % rhenium, about 0.4 wt % lanthanide elements, and the balance being nickel and incidental impurities. This nickel-based superalloy composition may be used in superalloy articles, such as a blade, nozzle, a shroud, a splash plate, a squealer tip of the blade, and a combustor of a gas turbine engine.

Abstract: A composition of matter includes from about 16 to about 20 wt % chromium, greater than 6 to about 10 wt % aluminum, from about 2 to about 10 wt % iron, less than about 0.04 wt % yttrium, less than about 12 wt % cobalt, less than about 1.0 wt % manganese, less than about 1.0 wt % molybdenum, less than about 1.0 wt % silicon, less than about 0.25 wt % carbon, about 0.03 wt % boron, less than about 1.0 wt % tungsten, less than about 1.0 wt % tantalum, about 0.5 wt % titanium, about 0.5 wt % hafnium, about 0.5 wt % rhenium, about 0.4 wt % lanthanide elements, and the balance being nickel and incidental impurities. This nickel-based superalloy composition may be used in superalloy articles, such as a blade, nozzle, a shroud, a splash plate, a squealer tip of the blade, and a combustor of a gas turbine engine.

Abstract: A method of welding a superalloy component includes the following sequential steps. A welding step for welding a cavity using a filler metal in an inert atmosphere, where the cavity is located in the component. A covering step for covering the filler metal and a portion of the component with a weld filler layer in the inert atmosphere. The weld filler layer has a greater ductility than material comprising the component and/or material comprising the filler metal. A second covering step for covering the weld filler layer with a braze material, and subsequently performing a brazing operation. A heat treating step heat treats the component.