Abstract: A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.

Abstract: An apparatus for manufacturing an axi-symmetric part. The apparatus includes a vessel configured to contain the powder. The vessel is also configured to receive a part such that at least a portion of the part contacts the powder contained within the vessel. A first energy source is configured to generate a first beam of energy. The first beam of energy is configured to melt the powder at a first predetermined location such that the melted powder fuses to the part.

Abstract: Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone including a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.

Abstract: A bladed disk for a gas turbine engine is provided. The bladed disk includes a rotor disk, a plurality of rotor blades, and an interlocking transition zone. The rotor disk includes a plurality of fused layers of a first material formed via additive manufacturing and defines an outer rim. The plurality of rotor blades includes a plurality of fused layers of a second material formed via additive manufacturing. The interlocking transition zone includes a plurality of projections alternately extending from the outer rim of the rotor disk and the plurality of rotor blades, respectively, to undetachably couple the rotor disk and the plurality of rotor blades.

Abstract: A system and method for three-dimensional printing are provided. One three-dimensional printing system includes a first printing surface configured to hold a first three-dimensional object. The three-dimensional printing system also includes a second printing surface configured to hold a second three-dimensional object. The three-dimensional printing system includes at least one printing head disposed adjacent to the first and second printing surfaces for printing the first and second three-dimensional objects. A vertical position of the first printing surface is controlled independently from a vertical position of the second printing surface.

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.

Abstract: Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.

Abstract: An apparatus for manufacturing an axi-symmetric part. The apparatus includes a vessel configured to contain the powder. The vessel is also configured to receive a part such that at least a portion of the part contacts the powder contained within the vessel. A first energy source is configured to generate a first beam of energy. The first beam of energy is configured to melt the powder at a first predetermined location such that the melted powder fuses to the part.

Abstract: The present invention relates to a ceramic or metallic component including a first region having a first porosity ranging between 1 and 30%. The component includes a second region having a second porosity that is less than the first porosity. The component includes at least one graded transition between the first and second regions.

Abstract: A method of joining two components using additive manufacturing is provided. The method includes forming a first component made of a first material; forming an interlocking transition zone from the first material and a second material; and forming a second component made of the second material. The interlocking transition zone includes a plurality of projections alternately extending from the first component and the second component, respectively, to undetachably couple the first component and the second component.

Abstract: A rotor blade formed via additive manufacturing is provided. The rotor blade includes an airfoil and a coupled component. The airfoil includes a plurality of fused layers of a first material formed via additive manufacturing and defines a leading edge and a tip at a distal end. The coupled component includes a plurality of fused layers of a second material formed via additive manufacturing. An interlocking transition zone includes a plurality of projections alternately extending from the airfoil and the coupled component, respectively, to undetachably couple the airfoil and the coupled component.

Abstract: A bladed disk for a gas turbine engine is provided. The bladed disk includes a rotor disk, a plurality of rotor blades, and an interlocking transition zone. The rotor disk includes a plurality of fused layers of a first material formed via additive manufacturing and defines an outer rim. The plurality of rotor blades includes a plurality of fused layers of a second material formed via additive manufacturing. The interlocking transition zone includes a plurality of projections alternately extending from the outer rim of the rotor disk and the plurality of rotor blades, respectively, to undetachably couple the rotor disk and the plurality of rotor blades.

Abstract: Turbine nozzles are provided for gas turbine engines. The turbine nozzle includes an arcuate inner band; an arcuate outer band; and a nozzle vane disposed between the arcuate inner band and the arcuate outer band. The radially inner end of the nozzle vane is attached to the arcuate inner band through an interlocking transition zone comprising a plurality of projections alternately extending from the radially inner end of the nozzle vane and the arcuate inner band, respectively, to undetachably couple the nozzle vane and the arcuate inner band. Optionally, the radially outer end of each nozzle vane is also attached to the arcuate outer band through an interlocking transition zone.

Abstract: Methods for repairing surface of a metal substrate are provided, which can include preparing the surface of the metal substrate for repair; melt attaching a base layer onto the surface of the metal substrate; fusing a plurality of first layers of a first material via additive manufacturing to the base coating; forming an interlocking transition zone via additive manufacturing from the first material and a second material; and fusing a plurality of second layers of the second material via additive manufacturing on the interlocking transition zone. The interlocking transition zone can have a plurality of projections alternately extending from the plurality of first layers and the plurality of second layers, respectively, to undetachably couple the plurality of first layers to the plurality of second layers. A repaired metal substrate is also provided.

Abstract: A composite core die includes a reusable core die; and a disposable core die. The disposable core die is in physical communication with the reusable core die and surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.

Abstract: Hybrid turbine airfoil components containing a ceramic material, in which detailed features of the components are formed of materials other than ceramic materials. The components include a first component formed of a ceramic-based material and a second component formed of a metallic material. The first component comprises an airfoil portion and a nub, and the second component is separately formed and attached to the first component by casting the metallic material around the nub of the first component. The second component includes a platform portion between the airfoil portion and the nub of the first component and a dovetail portion on the nub of the first component. Each of the platform and dovetail portions has at least one off-axis geometric feature that results in the second component having a more complex geometry than the first component.

Abstract: Hybrid components containing a ceramic material, in which detailed features of the components are formed of materials other than ceramic materials, yet result in a robust mechanical attachment of the ceramic and non-ceramic portions of the components. The components includes a first subcomponent formed of a ceramic-based material and a second subcomponent formed of a metallic material. The first subcomponent has a nub and the second subcomponent is separately formed and attached to the first subcomponent by casting the metallic material around the nub of the first subcomponent. The second subcomponent is attached to the first subcomponent by a compression fit and encapsulation of the second subcomponent on the nub of the first subcomponent. The nub has a compliant coating system that provides thermal expansion compliance between the metallic material of the second subcomponent and the ceramic-based material of the first subcomponent.

Abstract: Processes for producing a component containing a ceramic-based material and having detailed features formed from materials other than ceramic materials. Such a process entails producing the component to include a first subcomponent and at least a second subcomponent having at least one off-axis geometric feature that results in the second subcomponent having a more complex geometry than the first subcomponent. The first subcomponent is formed of a ceramic-based material, and the second subcomponent and its off-axis geometric feature are separately formed of a metallic material and attached to the first subcomponent to yield a robust mechanical attachment. The component may be, for example, a gas turbine airfoil component.

Abstract: A system and method for three-dimensional printing are provided. One three-dimensional printing system includes a first printing surface configured to hold a first three-dimensional object. The three-dimensional printing system also includes a second printing surface configured to hold a second three-dimensional object. The three-dimensional printing system includes at least one printing head disposed adjacent to the first and second printing surfaces for printing the first and second three-dimensional objects. A vertical position of the first printing surface is controlled independently from a vertical position of the second printing surface.

Abstract: A composite core die includes a reusable core die; and a disposable core die. The disposable core die is in physical communication with the reusable core die and surfaces of communication between the disposable core die and the reusable core die serve as barriers to prevent the leakage of a slurry that is disposed in the composite core die.