System having layered structure and method of making the same

Patent metadata

Field	Value
Publication number	US-9649690-B2
Application number	US-201414189734-A
Country	US
Kind code	B2
Filing date	Feb 25, 2014
Priority date	Feb 25, 2014
Publication date	May 16, 2017
Grant date	May 16, 2017

Abstract

A system includes a layered structure. The layered structure includes first and second coalesced layers and an intermediate layer disposed between the first and second coalesced layers. The first and second coalesced layers have a higher degree of coalescence than the intermediate layer.

First claim

The invention claimed is:

1. A system, comprising:
a turbomachine component having a layered structure, the layered structure comprising:
a first coalesced layer;
a second coalesced layer; and
an intermediate layer disposed between the first and second coalesced layers, wherein the first and second coalesced layers have a higher degree of coalescence than the intermediate layer and wherein the intermediate layer comprises an evacuated region configured to serve as a thermal barrier, an acoustic barrier, or a combination thereof between at least a first portion of the first coalesced layer and a second portion of the second coalesced layer.

2. The system of claim 1 , wherein the turbomachine component is a turbine nozzle, turbine frame, seal, combustor liner, combustor cap, fuel nozzle, compressor blade, turbine blade, compressor wheel, turbine wheel, shroud segment, gas pre-mixer, liquid fuel injector, combustor-to-turbine transition piece, or any combination thereof.

3. The system of claim 1 , wherein the system comprises a rotary machine system, a hot gas path machine system, or a combination thereof.

4. The system of claim 1 , wherein at least one of the first coalesced layer, the second coalesced layer, or the intermediate layer comprises functionally graded materials.

5. The system of claim 1 , wherein the intermediate layer comprises at least one of partially coalesced cobalt-chromium, stainless steel, titanium, a chromium-nickel based alloy, or a nickel based alloy.

6. The system of claim 1 , wherein the first coalesced layer, the second coalesced layer, the intermediate layer, or any combination thereof, have a plurality of respective regions, wherein each region of the plurality of regions has a different degree of coalescense.

7. The system of claim 1 , wherein at least one of the first coalesced layer, the second coalesced layer, or the intermediate layer, has varying cross-sectional thickness throughout at least a portion of the layered structure.

8. The system of claim 1 , wherein the first coalesced layer is directly connected to the second coalesced layer by one or more extensions passing through the intermediate layer.

9. The system of claim 1 , wherein the first coalesced layer is a first sintered layer, and wherein the second coalesced layer is a second sintered layer.

10. The system of claim 9 , wherein the first sintered layer is fully sintered, the second sintered layer is fully sintered, or a combination thereof.

11. The system of claim 1 , wherein the first coalesced layer and the second coalesced layer comprise coalesced powder.

12. The system of claim 11 , wherein the coalesced powder is coalesced via Direct Metal Laser Sintering, Direct Metal Laser Melting, Selective Laser Sintering, Electron Beam Melting, or a combination thereof.

13. The system of claim 1 , wherein the first coalesced layer is coalesced to a first degree, the second coalesced layer is coalesced to a second degree, and the first degree is different than the second degree.

Assignees

• Gen Electric

Inventors

• Mcmahan Kevin Weston
• Myers Geoffrey David

Classifications

• B23K15/0093 Primary

  characterised by the properties of the materials to be welded · CPC title

• B22F12/70

  Gas flow means · CPC title

• B22F12/226

  for rotary motion · CPC title

• B22F10/25

  Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS] · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title