Abstract: A process for providing a manufacturing modality for a hybrid article includes defining a model for a build surface on a part in a three dimensional space, and defining a model for an additive structure, the model including an interface surface of the additive structure that corresponds with the build surface in the three dimensional space. The process further includes orienting the x, y and z coordinates of each of the build surface of the part and the interface surface of the model in relation to a three dimensional work space, aligning contours of each of the build surface and the interface surface relative to the work space, and directing a cladding system to define toolpaths for two or more cladding layers that are defined by vertical planar segments or slices of the additive structure model.

Abstract: Described is a nozzle assembly that includes a body component defining a center axis. The nozzle assembly also includes an energy beam channel and substantially collinear with the center axis. The energy beam channel has an inlet portion and an outlet portion oriented to pass an energy beam therethrough. At least one side-feeding powder tube extends through the body component at an angle with respect to the center axis. The side-feeding powder tube discharges a powdered material into a focus point of the energy beam. The angle is selected to generate a powder concentration spot diameter that is about twice a beam focus point diameter of the energy beam focus point.

Abstract: A method for forming an article is disclosed, including laser welding a powder of an HTW alloy to a surface of a substrate along a weld path, forming a weld bead of the HTW alloy. The weld path is propagated along a weld direction, forming a cladding layer of the HTW alloy on the surface. The laser welding includes a laser energy density of at least about 11 kJ/cm2, and laser welding the powder to the surface includes a welding speed of about 5-20 ipm. The weld path oscillates essentially nonparallel to a reference line, establishing a cladding width wider than the weld bead width. The weld bead contacts itself along each oscillation such that the cladding layer is continuous and essentially free of cracks. A turbine bucket is disclosed including a squealer tip having the cladding layer with a cladding layer thickness of at least about 0.2 inches.

Abstract: A process for providing a manufacturing modality for a hybrid article includes defining a model for a build surface on a part in a three dimensional space, and defining a model for an additive structure, the model including an interface surface of the additive structure that corresponds with the build surface in the three dimensional space. The process further includes orienting the x, y and z coordinates of each of the build surface of the part and the interface surface of the model in relation to a three dimensional work space, aligning contours of each of the build surface and the interface surface relative to the work space, and directing a cladding system to define toolpaths for two or more cladding layers that are defined by vertical planar segments or slices of the additive structure model.

Abstract: Described is a nozzle assembly that includes a body component defining a center axis. The nozzle assembly also includes an energy beam channel and substantially collinear with the center axis. The energy beam channel has an inlet portion and an outlet portion oriented to pass an energy beam therethrough. At least one side-feeding powder tube extends through the body component at an angle with respect to the center axis. The side-feeding powder tube discharges a powdered material into a focus point of the energy beam. The angle is selected to generate a powder concentration spot diameter that is about twice a beam focus point diameter of the energy beam focus point.

Abstract: A component treatment processes and treated gas turbine components are disclosed. The gas turbine treatment process includes laser-removing coating from a substrate of a turbine component to form laser-induced plasma, spectroscopically analyzing the laser-induced plasma, and discontinuing the laser-removing in response to the spectroscopic analyzing. The treated gas turbine component includes a laser-affected surface, the laser-affected surface having one or both of modified dimensions and modified microstructure due to being exposed to the laser-removing of the coating. The laser-affected surface has a depth corresponding to the laser-removing being discontinued based upon the spectroscopic analyzing of the laser-induced plasma formed from the laser-removing.

Abstract: Methods for modifying bucket platforms of turbine buckets include removing a portion of the bucket platform to form a void, wherein the void comprises a predetermined geometry, and adding a filler material in a plurality of layers to fill the void.

Abstract: Methods for modifying a turbine buckets include removing at least an original outer edge for an entire length of the slash face of the turbine bucket and adding a new material to the slash face to build a new outer edge, wherein the new outer edge extends the entire length of the slash face.