Abstract: A turbine nozzle formed of a superalloy, and including: an annular end-wall including a pocket, the pocket defining an inner surface within the annular end-wall; a vane, the vane including an airfoil portion and a boss portion, the vane extending from the pocket such that the boss portion is enclosed within the pocket and the airfoil portion extends through the annular end-wall; and a seal within the pocket, the seal including one or more protrusions extending from the inner surface of the pocket and abutting the vane at one or both of the boss portion and the airfoil portion.

Abstract: A turbine nozzle formed of a superalloy, and including: an annular end-wall including a pocket, the pocket defining an inner surface within the annular end-wall; a vane, the vane including an airfoil portion and a boss portion, the vane extending from the pocket such that the boss portion is enclosed within the pocket and the airfoil portion extends through the annular end-wall; and a seal within the pocket, the seal including one or more protrusions extending from the inner surface of the pocket and abutting the vane at one or both of the boss portion and the airfoil portion.

Abstract: A method for manufacturing an article, including: providing a three-dimensional computer model of the article; providing a Al—Fe—V—Si metal alloy in powdered form comprising a plurality of powder particles; coating the plurality of powder particles with a coating of silicon using a chemical vapor deposition process; at a powder bed additive manufacturing apparatus, supplying the coated metal alloy and loading the three-dimensional model; and using the powder bed additive manufacturing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied coated metal alloy.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is a gamma prime precipitation hardened nickel-based superalloy. The powdered form includes a grain size range of about 5 to about 22 microns and a d50 grain size average of about 10 to about 13 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100° F. per minute.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is a titanium aluminide alloy. The powdered form includes a grain size range of about 5 to about 20 microns and a d50 grain size average of about 10 to about 14 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100 ° F. per minute.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is an aluminum-iron-vanadium-silicon alloy. The powdered form includes a grain size range of about 5 to about 22 microns and a d50 grain size average of about 10 to about 13 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100° F. per minute.

Abstract: Methods for manufacturing an article include providing a three-dimensional computer model of the article and providing a metal alloy in powdered form. The metal alloy is a nickel-chromium-tungsten-molybdenum alloy. The powdered form includes a grain size range of about 5 to about 22 microns and a d50 grain size average of about 10 to about 13 microns. The methods further include, at a binder jet printing apparatus, supplying the metal alloy and loading the three-dimensional model, and, using the binder jet printing apparatus, manufacturing the article in accordance with the loaded three-dimensional model in a layer-by-layer manner with the supplied metal alloy. A liquid binder is applied at each layer, and each layer has a thickness of about 10 to about 150 microns. The methods avoid remelting of the metal alloy and avoid metal alloy cooling rates of greater than about 100° F. per minute.