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: 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: 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: 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: A composite article, for example a blading member of a gas turbine engine, comprising a plurality of stacked layers of in-plane reinforcing fibers bonded together with a matrix resin is provided with enhanced resistance to impact cracking, material loss and/or delamination through use of a plurality of spaced apart reinforcing pins disposed into the article at an angle to the stacked layers, in one form disposed in a selected article region generally to resist strain energy generated during operation of the region. In another form, enhanced resistance is provided through the combination of a matrix resin including properties comprising a tensile strain property of at least 5% and a K1c toughness of at least about 850 psi·inch1/2, and a plurality of spaced apart reinforcing pins disposed into the article at an angle to the stacked layers.

Abstract: A composite article, for example a blading member of a gas turbine engine, comprising a plurality of stacked layers of in-plane reinforcing fibers bonded together with a matrix resin is provided with enhanced resistance to impact cracking, material loss and/or delamination through use of a plurality of spaced apart reinforcing pins disposed into the article at an angle to the stacked layers, in one form disposed in a selected article region generally to resist strain energy generated during operation of the region. In another form, enhanced resistance is provided through the combination of a matrix resin including properties comprising a tensile strain property of at least 5% and a K1c toughness of at least about 850 psi·inch1/2, and a plurality of spaced apart reinforcing pins disposed into the article at an angle to the stacked layers.