Patent Publication Number: US-10767501-B2

Title: Article, component, and method of making a component

Description:
FIELD OF THE INVENTION 
     The present embodiments are directed to an article, a component, and a method of making a component. More specifically, the present embodiments are directed to a contoured article, a component including a contoured article, and a method of making a component including a contoured article. 
     BACKGROUND OF THE INVENTION 
     Hot gas path components within gas turbine engines are continuously exposed to elevated temperatures during normal operation. As gas turbines are modified to increase efficiency and decrease cost, the temperatures within the hot gas path are being increased while the geometries of the components are becoming more complex. In order to continue increasing the temperatures within the hot gas path, the turbine components in this area must be constructed of materials which can withstand such temperatures. 
     Typically, manufacturing and servicing of hot gas path components, such as nozzles, includes applying a material over a portion of the component. For example, servicing of hot gas path nozzles often includes brazing a sheet of material to an end wall of the nozzle. The end wall of the nozzle is usually contoured to provide a desired air flow thereover, while the sheets of material that are applied to the contoured end wall are generally flat. To maintain the contour of the end wall, the flat sheets are conformed to the contoured end wall during brazing. 
     However, the conforming of the flat sheet to the contoured end wall forms gaps in the bond interface between the material and the end wall. The gaps are often filled with air, which decreases heat transfer between the material and the end wall. The decrease in cooling effectiveness decreases efficiency of the turbine system and/or increases operating cost. 
     SUMMARY OF THE INVENTION 
     In an embodiment, an article includes a contoured proximal face and a contoured distal face. The contoured proximal face is arranged and disposed to substantially mirror a contour of at least one of an end wall and an airfoil outer surface of a component. 
     In another embodiment, a component includes a first end wall, a second end wall, an airfoil with an airfoil outer surface positioned between the first end wall and the second end wall, and an article secured to at least one of the first end wall, the second end wall, and the airfoil outer surface. The article includes a contoured proximal face and a contoured distal face. The contoured proximal face substantially mirrors a contour of at least one of the first end wall, the second end wall, and the airfoil outer surface. 
     In another embodiment, a method of making a component includes forming an article having a proximal face and a distal face, contouring the proximal face of the article to form a contoured proximal face, and securing the contoured proximal face of the article to at least one of a first end wall, a second end wall, and the airfoil portion of the component. Prior to the step of securing, the contoured proximal face substantially mirrors a contour of at least one of the first end wall, the second end wall, and the airfoil portion of the component. 
     Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is perspective view of a component, according to an embodiment of the disclosure. 
         FIG. 2  is a perspective view of the component of  FIG. 1  and an article to be secured to the lower end wall of the component, according to an embodiment of the disclosure. 
         FIG. 3  is a perspective view of the component of  FIG. 1  and an article to be secured to the upper end wall of the component, according to an embodiment of the disclosure. 
         FIG. 4  is a perspective view of the component of  FIG. 1  and an article being secured to the airfoil surface of the component by a method of forming the component, according to an embodiment of the disclosure. 
         FIG. 5  is a process view of a method of forming a component, according to an embodiment of the disclosure. 
         FIG. 6  is an enlarged view of an article positioned over an end wall of a component, according to an embodiment of the disclosure. 
         FIG. 7  is an enlarged view of a prior art article positioned over an end wall of a component. 
         FIG. 8  is a process view of a method of forming a component, according to another embodiment of the disclosure. 
     
    
    
     Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Provided are an article, a component, and a method of making a component. Embodiments of the present disclosure, for example, in comparison to concepts failing to include one or more of the features disclosed herein, decrease or eliminate the formation of gaps within a component, increase cooling effectiveness of a component, provide a closer tolerance between components and braze sheets, increase joint quality between braze sheets and components, increase component life, increase manufacturing efficiency, increase manufacturing yield, facilitate use of increased system temperatures, increase system efficiency, or a combination thereof. 
     Referring to  FIG. 1 , a component  100  includes any combustion and/or turbine component having surfaces that are exposed to elevated temperatures, such as, but not limited to, a shroud, a blade, a bucket, any other hot gas path component, or a combination thereof. For example, in one embodiment, the component  100  includes a nozzle  101  configured for use in a hot gas path of a turbine engine. In another embodiment, the nozzle  101  includes an airfoil portion  103  positioned between a first end wall  105  and a second end wall  107 . In a further embodiment, as illustrated in  FIGS. 2-4 , the component  100  includes at least one article  201  secured to the first end wall  105  ( FIG. 2 ) and/or the second end wall  107  ( FIG. 3 ) and/or the airfoil portion  103  ( FIG. 4 ) thereof. Although shown in  FIGS. 2-4  as being secured to the first end wall  105 , the second end wall  107 , or the airfoil portion  103 , as will be appreciated by those skilled in the art, the disclosure is not so limited and may include at least one of the articles  201  secured to any one, two, or all three of the first end wall  105 , the second end wall  107 , and the airfoil portion  103 . 
     According to one or more of the embodiments disclosed herein, the article  201  may be secured to the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103  through any suitable method, such as, but not limited to, brazing, sintering, welding, or a combination thereof. The component  100  includes any suitable material having any suitable microstructure for continuous use in a turbine engine and/or within the hot gas path of the turbine engine. Suitable microstructures include, but are not limited to, equiaxed, directionally solidified (DS), single crystal (SX), or a combination thereof. Suitable materials of the component  100  include, but are not limited to, a metal, a ceramic, an alloy, a superalloy, steel, a stainless steel, a tool steel, nickel, cobalt, chrome, titanium, aluminum, or a combination thereof. 
     For example, in one embodiment, the material of the component  100  is a cobalt-based material including, but not limited to, a composition, by weight, of about 29% chromium (Cr), about 10% nickel (Ni), about 7% tungsten (W), about 1% iron (Fe), about 0.25% carbon (C), about 0.01% boron (B), and a balance of cobalt (Co) (e.g., FSX414); about 20% to about 24% Cr, about 20% to about 24% Ni, about 13% to about 15% W, about 3% Fe, about 1.25% manganese (Mn), about 0.2% to about 0.5% silicon (Si), about 0.015% B, about 0.05% to about 0.15% C, about 0.02% to about 0.12% lanthanum (La), and a balance of Co (e.g., HAYNES® 188); about 22.5% to about 24.25% Cr, about 9% to about 11% Ni, about 6.5% to about 7.5% W, about 3% to about 4% tantalum (Ta), up to about 0.3% titanium (Ti) (e.g., about 0.15% to about 0.3% Ti), up to about 0.65% C (e.g., about 0.55% to about 0.65% C), up to about 0.55% zirconium (Zr) (e.g., about 0.45% to about 0.55% Zr), and a balance of Co (e.g., Mar-M-509); or about 20% Ni, about 20% Cr, about 7.5% Ta, about 0.1% Zr, about 0.05% C, and a balance of Co (e.g., Mar-M-918). 
     In another embodiment, the material of the component  100  is a nickel-based material including, but not limited to, a composition, by weight, of about 9.75% Cr, about 7.5% Co, about 6.0% W, about 4.2% aluminum (Al), about 3.5% Ti, about 1.5% molybdenum (Mo), about 4.8% Ta, about 0.5% niobium (Nb), about 0.15% hafnium (Hf), about 0.05% C, about 0.004% B, and a balance of Ni (e.g., René N4); about 7.5% Co, about 7.0% Cr, about 6.5% Ta, about 6.2% Al, about 5.0% W, about 3.0% rhenium (Re), about 1.5% Mo, about 0.15% Hf, about 0.05% C, about 0.004% B, about 0.01% yttrium (Y), and a balance of Ni (e.g., René N5); refers to an alloy including a composition, by weight, of about 7.5% Co, about 13% Cr, about 6.6% Al, about 5% Ta, about 3.8% W, about 1.6% Re, about 0.15% Hf, and a balance of Ni (e.g., René N2); between about 9% and about 10% Co, between about 9.3% and about 9.7% W, between about 8.0% and about 8.7% Cr, between about 5.25% and about 5.75% Al, between about 2.8% and about 3.3% Ta, between about 1.3% and about 1.7% Hf, up to about 0.9% Ti (for example, between about 0.6% and about 0.9%), up to about 0.6% Mo (for example, between about 0.4% and about 0.6%), up to about 0.2% Fe, up to about 0.12% Si, up to about 0.1% Mn, up to about 0.1% copper (Cu), up to about 0.1% C (for example, between about 0.07% and about 0.1%), up to about 0.1% Nb, up to about 0.02% Zr (for example, between about 0.005% and about 0.02%), up to about 0.02% B (for example, between about 0.01% and about 0.02%), up to about 0.01% phosphorus (P), up to about 0.004% sulfur (S), and a balance of Ni (e.g., René 108); about 13.70% to about 14.30% Cr, about 9.0% to about 10.0% Co, about 4.7% to about 5.1% Ti, about 3.5% to about 4.1% W, about 2.8% to about 3.2% Al, about 2.4% to about 3.1% Ta, about 1.4% to about 1.7% Mo, 0.35% Fe, 0.3% Si, about 0.15% Nb, about 0.08% to about 0.12% C, about 0.1% Mn, about 0.1% Cu, about 0.04% Zr, about 0.005% to about 0.020% B, about 0.015% P, about 0.005% S, and a balance of Ni (e.g., GTD-111®, available from General Electric Company); about 22.2% to about 22.8% Cr, about 18.5% to about 19.5% Co, about 2.3% Ti, about 1.8% to about 2.2% W, about 1.2% Al, about 1.0% Ta, about 0.8% Nb, about 0.25% Si, about 0.08% to about 0.12% C, about 0.10% Mn, about 0.05% Zr, about 0.008% B, and a balance of Ni (e.g., GTD-222®, available from General Electric Company); about 9.75% Cr, about 7.5% Co, about 6.0% W, about 4.2% Al, about 4.8% Ta, about 3.5% Ti, about 1.5% Mo, about 0.08% C, about 0.009% Zr, about 0.009% B, and a balance of Ni (e.g., GTD-444®, available from General Electric Company); about 15.70% to about 16.30% Cr, about 8.00% to about 9.00% Co, about 3.20% to about 3.70% Ti, about 3.20% to about 3.70% Al, about 2.40% to about 2.80% W, about 1.50% to about 2.00% Ta, about 1.50% to about 2.00% Mo, about 0.60% to about 1.10% Nb, up to about 0.50% Fe, up to about 0.30% Si, up to about 0.20% Mn, about 0.15% to about 0.20% C, about 0.05% to about 0.15% Zr, up to about 0.015% S, about 0.005% to about 0.015% B, and a balance of Ni (e.g., INCONEL® 738); or about 9.3% to about 9.7% W, about 9.0% to about 9.5% Co, about 8.0% to about 8.5% Cr, about 5.4% to about 5.7% Al, up to about 0.25% Si, up to about 0.1% Mn, about 0.06% to about 0.09% C, incidental impurities, and a balance of Ni (e.g., Mar-M-247). 
     In a further embodiment, the material of the component  100  is an iron-based material including, but not limited to, a composition, by weight, of about 50% to about 55% Ni and Co combined, about 17% to about 21% Cr, about 4.75% to about 5.50% Nb and Ta combined, about 0.08% C, about 0.35% Mn, about 0.35% Si, about 0.015% P, about 0.015% S, about 1.0% Co, about 0.35% to 0.80% Al, about 2.80% to about 3.30% Mo, about 0.65% to about 1.15% Ti, about 0.001% to about 0.006% B, about 0.15% Cu, and a balance of Fe (e.g., INCONEL® 718). Other materials of the component  100  include, but are not limited to, a CoCrMo alloy, such as, for example, 70Co-27Cr-3Mo; a ceramic matrix composite (CMC); or a combination thereof. 
     “INCONEL” is a federally registered trademark of alloys produced by Huntington Alloys Corporation, Huntington, W. Va. “HAYNES” is a federally registered trademark of alloys produced by Haynes International, Inc., Kokomo, Ind. 
     The article  201  includes any material suitable for being secured directly or indirectly to the first end wall  105  and/or the second end wall  107 , and/or for continuous use in a turbine engine and/or within the hot gas path of the turbine engine. In some embodiments, the article  201  is a single piece. In other embodiments, the article  201  is provided as multiple pieces. The number of pieces in which the article  201  is provided may depend on how much surface area coverage is required for the component  100  and the complexity of the flow path surface contours on the article  201  or on the component  100 . 
     The material of the article  201  may be the same, substantially the same, or different from the material of the component  100 . In one embodiment, the material of the article  201  includes a pre-sintered preform (PSP). In another embodiment, the PSP contains at least two materials with various mixing percentages. A first material includes, for example, any of the materials suitable for the hot-gas path of a turbine system disclosed herein. A second material includes, for example, a braze alloy, such as, but not limited to, a nickel braze alloy material having a composition, by weight, of between about 13% and about 15% Cr, between about 9% and about 11% Co, between about 2.25% and about 2.75% Ta, between about 3.25% and about 3.75% Al, between about 2.5% and about 3% B, up to about 0.1% Y (for example, between about 0.02% and about 0.1% Y), and a balance of Ni; or between about 18.5% and about 19.5% Cr, between about 9.5% and about 10.5% Si, about 0.1% Co, about 0.03% B, about 0.06% C, and a balance of Ni. 
     In some embodiments, the first material is a high melt powder and the second material is a low melt powder. The material of the article  201  is therefore a mixture of a high melt powder and a low melt powder sintered to make the article  201  rigid. The ratio of high melt powder to low melt powder is preferably in the range of 70:30 to 35:65, alternatively in the range of 60:40 to 45:55, alternatively 60:40, or ranges or sub-ranges therebetween. 
     In some embodiments, the high melt powder is a composition, by weight, including, but not limited to, about 9.3% to about 9.7% W, about 9.0% to about 9.5% Co, about 8.0% to about 8.5% Cr, about 5.4% to about 5.7% Al, up to about 0.25% Si, up to about 0.1% Mn, about 0.06% to about 0.09% C, incidental impurities, and a balance of Ni (e.g., Mar-M-247); about 6.8% Cr, about 12% Co, about 6.1% Al, about 4.9% W, about 1.5% Mo, about 2.8% Re, about 6.4% Ta, about 1.5% Hf, and a balance of Ni (e.g., René 142); about 7.6% Cr, about 3.1% Co, about 7.8% Al, about 5.5% Ta, about 0.1% Mo, about 3.9% W, about 1.7% Re, about 0.15% Hf, and a balance of Ni (e.g., René 195); or about 7.5% Co, about 13% Cr, about 6.6% Al, about 5% Ta, about 3.8% W, about 1.6% Re, about 0.15% Hf, and a balance of Ni (e.g., René N2). 
     In some embodiments, the low melt powder is a composition, by weight, including, but not limited to, about 71% Ni, about 19% Cr, and about 10% Si (e.g., AMS4782); about 14.0% Cr, about 10.0% Co, about 3.5% Al, about 2.7% B, about 0.02% Y, and a balance of Ni (e.g., DF4B); between about 13% and about 15% Cr, between about 9% and about 11% Co, between about 3.2% and about 3.8% Al, between about 2.2% and about 2.8% Ta, between about 2.5% and about 3.0% B, up to about 0.10% Y (optionally present), and a balance of Ni; between about 14% and about 16% Co, between about 19% and about 21% Cr, between about 4.6% and about 5.4% Al, a maximum of about 0.02% B, a maximum of about 0.05% C, between about 7.5% and about 8.1% Si, a maximum of about 0.05% Fe, and a balance of Ni; or about 15.3% Cr, about 10.3% Co, about 3.5% Ta, about 3.5% Al, about 2.3% B, and a balance of Ni. 
     In some embodiments, material of the article  201  is a high melt powder of Mar-M-247, a low melt powder of AMS4782 and the ratio of high melt powder to low melt powder is 60:40. 
     Multiple powders may be mixed to get the predetermined desired properties and braze temperature. The PSP pieces may be held in place on one or more of the nozzle surfaces by tack welding to enable positioning and retention of the article  201  during a brazing cycle. More specifically, the tack welding may involve resistance welding or fusion welding. In some embodiments, the brazing is vacuum brazing. 
     In some embodiments, after the article  201  is secured to the component  100 , a bond coat followed by a thermal barrier coating are applied to the article  201  and/or the component  100 . 
     In one embodiment, the article  201  includes a contoured proximal face  202  and a contoured distal face  203 . The contoured proximal face  202  and/or the contoured distal face  203  are formed through any suitable method, such as, but not limited to, contouring of the article  201  during manufacturing, contouring of the article  201  after manufacturing, bending of the article  201 , machining of the article  201 , or a combination thereof. The contoured proximal face  202  and the contoured distal face  203  may also be formed simultaneously or separately, and include the same, substantially the same, or different shapes and/or contours. 
     Referring to  FIGS. 4, 5, 6, and 8 , the contoured proximal face  202  is arranged and disposed for securing the article  201  directly or indirectly to the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103  of the component  100 . For example, in one embodiment, as illustrated in  FIGS. 4-5 , the contoured proximal face  202  is secured directly to the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 , and includes a shape and/or contour that, prior to securing the article  201  to the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 , mirrors or substantially mirrors the shape and/or contour of the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 . By “mirrors” or “substantially mirrors” it is meant that the contoured proximal face  202  of the article  201  has a geometry that follows a geometry of the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 , providing direct contact between the surfaces thereof. 
     In contrast to the article  601  with a flat surface  603  of  FIG. 7  that conforms to the first end wall  105  during the securing process, the shape and/or contour of the contoured proximal face  202  provides a closer tolerance between the article  201  and the first end wall  105  ( FIG. 6 ) and/or the second end wall  107  and/or the airfoil portion  103 . The closer tolerance provided by the article  201  decreases or eliminates the formation of gaps and/or increases joint quality between the article  201  and the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 . This increases manufacturing yield of the component  100 , increases a life cycle of the component  100 , increases cooling effectiveness of the component  100 , or a combination thereof. 
     Additionally, the contoured distal face  203 , which is positioned opposite or substantially opposite the contoured proximal face  202  with respect to the article  201 , forms an exterior surface over the first end wall  105  and/or the second end wall  107 . The exterior surface formed by the contoured distal face  203  may be the same, substantially the same, or different from the first end wall  105  and/or the second end wall  107 , and provides any suitable surface characteristic over the first end wall  105  and/or the second end wall  107 . For example, the surface characteristic may be the same as the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 , or may include a modified surface characteristic. Suitable modified surface characteristics include, but are not limited to, hardness, corrosion resistance, temperature resistance, machinability, or a combination thereof. 
     In an alternate embodiment, as illustrated in  FIG. 8 , at least one intermediate member  701  is positioned between the article  201  and the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 . The intermediate member  701  includes any material or combination of materials suitable for indirectly securing the article  201  to the first end wall  105  and/or the second end wall  107 . For example, in one embodiment, the intermediate members  701  includes a paste, slurry, powder, or other material configuration as an intermediate member  701  material for facilitating the securing of the article  201  to the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 . The intermediate member  701  may be used to prevent separation between multiple pieces when the article  201  pieces are set on the surface of the nozzle. The intermediate member  701  may be applied to enable smooth transitions to other features, if necessary. 
     In another embodiment, the intermediate member  701  includes a first surface and a second surface that are arranged and disposed to indirectly secure the article  201  to the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 . In a further embodiment, when the article  201  is indirectly secured to the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103  through the intermediate member  701 , the contoured distal face  203  forms the exterior surface over the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 . 
     Prior to securing, the first surface of the intermediate member  701  includes a shape and/or contour that mirrors or substantially mirrors the shape and/or contour of the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 , and the second surface of the intermediate member  701  includes a shape and/or contour that mirrors or substantially mirrors the shape and/or contour of the contoured proximal face  202  of the article  201 . When the first surface of the intermediate member  701  is secured to the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 , the second surface of the intermediate member  701  provides an intermediate surface over the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 . The intermediate surface facilitates securing of the contoured proximal face  202  thereto, which, in combination with the contoured proximal face  202 , provides closer tolerance between the article  201  and the first end wall  105  and/or the second end wall  107  and/or the airfoil portion  103 , as compared to the flat surface  603  shown in  FIG. 7 . 
     Any of the alloy compositions described herein may include incidental impurities. 
     While the invention has been described with reference to one or more embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. In addition, all numerical values identified in the detailed description shall be interpreted as though the precise and approximate values are both expressly identified.