Abstract: A method of forming an abrasive nickel-based alloy on a turbine blade tip includes producing or obtaining a metal powder that is mixed with a carbon powder to form a carbon-enriched metal powder. The metal powder includes a refractory element. The method further includes bonding the carbon-enriched metal powder to the turbine blade tip. The step of bonding includes raising the temperature of the carbon-enriched metal powder past its melting point, thereby causing the carbon to combine with the refractory elements to form abrasive carbide particles.

Abstract: Cladding material is applied by laser to a net-shape. A method of cladding a host component includes installing the component in a fixture. A shroud component is located against the host component adjacent a select location for the cladding. Cladding is applied to the host component to the select location and adjacent to shroud component so that the shroud component defines an edge of the cladding as applied. The edge of the cladding as defined by the shroud component defines a desired cladding profile requiring no/approximately no post-cladding processing to remove over-cladded material.

Abstract: A method of producing an abrasive tip for a turbine blade includes producing or obtaining a metal powder that is mixed with an abrasive ceramic powder and producing or obtaining a metallic mold that is in the shape of an airfoil. The metallic mold includes a hollow interior portion. The method further includes sealing the metal and ceramic powder mixture within the hollow interior portion of the metallic mold under vacuum and subjecting the sealed mold to a hot isostatic pressing process. The hot isostatic pressing process compacts and binds the metal and ceramic powder mixture together into a solid article in the shape of the airfoil. Still further, the method includes slicing the solid article into a plurality of airfoil-shaped slices and bonding one slice of the plurality of airfoil-shaped slices to a tip portion of a turbine blade.

Abstract: A method of producing an abrasive tip for a turbine blade includes producing or obtaining a metal powder that is mixed with an abrasive ceramic powder and producing or obtaining a metallic mold that is in the shape of an airfoil. The metallic mold includes a hollow interior portion. The method further includes sealing the metal and ceramic powder mixture within the hollow interior portion of the metallic mold under vacuum and subjecting the sealed mold to a hot isostatic pressing process. The hot isostatic pressing process compacts and binds the metal and ceramic powder mixture together into a solid article in the shape of the airfoil. Still further, the method includes slicing the solid article into a plurality of airfoil-shaped slices and bonding one slice of the plurality of airfoil-shaped slices to a tip portion of a turbine blade.

Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDIsK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDISK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

Abstract: A method of forming an abrasive nickel-based alloy on a turbine blade tip includes producing or obtaining a metal powder that is mixed with a carbon powder to form a carbon-enriched metal powder. The metal powder includes a refractory element. The method further includes bonding the carbon-enriched metal powder to the turbine blade tip. The step of bonding includes raising the temperature of the carbon-enriched metal powder past its melting point, thereby causing the carbon to combine with the refractory elements to form abrasive carbide particles.

Abstract: Cladding material is applied by laser to a net-shape. A method of cladding a host component includes installing the component in a fixture. A shroud component is located against the host component adjacent a select location for the cladding. Cladding is applied to the host component to the select location and adjacent to shroud component so that the shroud component defines an edge of the cladding as applied. The edge of the cladding as defined by the shroud component defines a desired cladding profile requiring no/approximately no post-cladding processing to remove over-cladded material.

Abstract: A method of manufacturing a directionally solidified article of the present disclosure includes providing a collection of particulate material and additively manufacturing a first article with an outer wall from the particulate material. The outer wall defines at least part of a cavity. The cavity contains an amount of the particulate material. The method also includes encasing at least a portion of the first article with an outer member. The outer member defines an internal cavity that corresponds to the first article. The method further includes heating the outer member and the first article to melt the first article into a molten mass within the internal cavity of the outer member. Additionally, the method includes solidifying the molten mass along a predetermined solidification path within the outer member to form a second article that corresponds to at least a portion of the internal cavity of the outer member.

Abstract: Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.

Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDISK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

Abstract: Dual alloy bladed rotors are provided, as are methods for manufacturing dual alloy bladed rotors. In one embodiment, the method includes arranging bladed pieces in a ring formation such that contiguous bladed pieces contact along shank-to-shank bonding interfaces. The ring formation is positioned around a hub disk, which is contacted by the bladed pieces along a shank-to-hub bonding interface. A metallic sealing material is deposited between contiguous bladed pieces utilizing, for example, a laser welding process to produce an annular seal around the ring formation. A hermetic cavity is then formed, which is circumferentially bounded by the annular seal and which encloses the shank-to-shank and shank-to-hub bonding interface. Afterwards, a Hot Isostatic Pressing process is performed during which the ring formation and the hub disk are exposed to elevated pressures external to the hermetic cavity sufficient to diffusion bond the shank-to-shank and shank-to-hub bonding interface.

Abstract: Hybrid bonded turbine rotors and methods for manufacturing the same are provided.

Abstract: A method for transient liquid phase bonding two metallic substrate segments together including the steps of forming a joined component by bringing together the two substrate segments along a bond line with a brazing alloy comprising a melting point depressant disposed between the two segments at the bond line and performing a first thermal treatment including heating the joined component at a brazing temperature of the brazing alloy for a first period of time. The method further includes performing a second thermal treatment including heating the joined component at an intermediate temperature that is above the brazing temperature but below a gamma prime solvus temperature of the substrate segments for a second period of time and performing a third thermal treatment including heating the joined component at a super-solvus temperature that is above the gamma prime solvus temperature of the two metallic substrate segments for a third period of time.

Abstract: Gas path components of gas turbine engines and methods for cooling the same using porous medium cooling systems are provided. The gas path component comprises a wall at least partially defining a cooling plenum and a porous medium cooling system. The wall includes a wall surface comprising a gas path surface and an opposing wall surface proximate the cooling plenum. The porous medium cooling system is disposed between the cooling plenum and the opposing wall surface. The porous medium cooling system comprises a perforated baffle and a porous material layer disposed between and adjacent the perforated baffle and the opposing wall surface. The wall includes a plurality of openings in fluid communication with the cooling plenum via the porous medium cooling system.

Abstract: A method of manufacturing a directionally solidified article of the present disclosure includes providing a collection of particulate material and additively manufacturing a first article with an outer wall from the particulate material. The outer wall defines at least part of a cavity. The cavity contains an amount of the particulate material. The method also includes encasing at least a portion of the first article with an outer member. The outer member defines an internal cavity that corresponds to the first article. The method further includes heating the outer member and the first article to melt the first article into a molten mass within the internal cavity of the outer member. Additionally, the method includes solidifying the molten mass along a predetermined solidification path within the outer member to form a second article that corresponds to at least a portion of the internal cavity of the outer member.

Abstract: Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.

Abstract: Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (TDISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (TBLADE_MAX) is established such that TBLADE_MAX is less than TDISK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than TDISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below TBLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

Abstract: Methods of forming dispersoid hardened metallic materials are provided. In an exemplary embodiment, a method of producing dispersoid hardened metallic materials includes forming a starting composition with a base metal component and a dispersoid forming component. The starting composition includes the base metal component in an amount from about 50 to about 99.999 weight percent and the dispersoid forming component in an amount from about 0.001 to about 1 weight percent, based on the total weight of the starting composition. A starting powder is formed from the starting composition, and the starting powder is fluidized with a fluidizing gas for a period of time sufficient to oxidize the dispersoid forming component to form the dispersoid hardened metallic material. The dispersoid forming component is oxidized while the starting powder is a solid.

Abstract: Dual alloy turbine rotors and methods for manufacturing the same are provided. The dual alloy turbine rotor comprises an assembled blade ring and a hub bonded to the assembled blade ring. The assembled blade ring comprises a first alloy selected from the group consisting of a single crystal alloy, a directionally solidified alloy, or an equi-axed alloy. The hub comprises a second alloy. The method comprises positioning a hub within a blade ring to define an interface between the hub and the blade ring. The interface is a non-contacting interface or a contacting interface. The interface is enclosed by a pair of diaphragms. The interface is vacuum sealed. The blade ring is bonded to the hub after the vacuum sealing step.