COMPOSITE COMPONENT HAVING ANGLED BRAZE JOINT, COUPON BRAZING METHOD AND RELATED STORAGE MEDIUM

• US 20180339354A1
• Filed: 05/25/2017
• Published: 11/29/2018
• Est. Priority Date: 05/25/2017
• Status: Active Grant

• Current Assignee: GE Infrastructure Technology, LLC (General Electric Company)
• Original Assignee: General Electric Company
• Inventors: Eminoglu, Cem Murat, DiMascio, Paul Stephen
• Granted Patent: US 10,456,849 B2
• Time in Patent Office: Days
• CPC Class Codes: B23K 1/0008 specially adapted for particular articles or work
• CPC Class Codes: B23K 1/0018 Brazing of turbine parts
• CPC Class Codes: B23K 1/19 taking account of the properties of the materials to be soldered
• CPC Class Codes: B23K 20/021 Isostatic pressure welding
• CPC Class Codes: B23K 2101/001 Turbines
• CPC Class Codes: B23K 2103/26 Alloys of Nickel and Cobalt and Chromium
• CPC Class Codes: B23P 6/005 using only replacement pieces of a particular form
• CPC Class Codes: F01D 5/005 Repairing methods or devices
• CPC Class Codes: F05D 2230/237 Brazing
• CPC Class Codes: F05D 2250/232 conical
• CPC Class Codes: Y02P 10/25 Process efficiency

Abstract

Various aspects include a composite component (also known as a Shear Enabled Regionally Engineered Facet (SEREF)) and methods of forming such a component. In some cases, a method includes: forming a slot in a main body of a metal alloy component, the slot extending at least partially through a wall of the metal alloy component, the forming of the slot including forming an angled main body interface in the wall of the metal alloy component; forming a coupon for coupling with the slot in the metal alloy component, the coupon having an angled coupon interface complementing the angled main body interface; and brazing the coupon to the main body at the slot to form a composite component.

Claims

1. A method comprising:

forming a slot in a main body of a metal alloy component, the slot extending at least partially through a wall of the metal alloy component, the forming of the slot including forming an angled main body interface in the wall of the metal alloy component;

forming a coupon for coupling with the slot in the metal alloy component, the coupon having an angled coupon interface complementing the angled main body interface; and

brazing the coupon to the main body at the slot to form a composite component.

2. The method of claim 1, wherein the metal alloy component includes a high-gamma prime alloy or a brittle alloy including:

René

125, René

80, René

N5, René

N4, René

108, GTD-111, GTD-444, Inconel (IN) 738, IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4, PWA1480, PWA1483, or PWA1484.

3. The method of claim 1, wherein the metal alloy component is a previously commissioned component exposed to operation within a machine.

4. The method of claim 1, wherein the angled main body interface and the angled coupon interface have an angle between approximately 10 degrees and approximately 45 degrees, as measured from a plane coincident with an outer surface of the main body.

5. The method of claim 1, wherein the angled main body interface and the angled coupon interface have an angle between approximately 10 degrees and approximately 25 degrees, as measured from a plane coincident with an outer surface of the main body.

6. The method of claim 1, wherein the forming of the slot in the main body includes cutting the metal alloy component, and wherein forming the coupon includes casting or additively manufacturing the coupon.

7. The method of claim 1, wherein the main body has an outer surface, and the coupon has:

a larger diameter (LD) spanning the slot across the outer surface of the main body; and

a smaller diameter (SD) spanning the slot across an inner surface of the main body, wherein the LD is defined by;

LD=((2*Z)/tan α

)+SD

wherein Z=a thickness of the wall and α

=an angle of the angled main body interface and the angled coupon interface, as measured relative to a plane coincident with the outer surface of the main body.

8. The method of claim 1, wherein the angled main body interface and the angled coupon interface are configured to bear a predominately shear stress in response to application of tension on the composite component.

9. The method of claim 1, wherein the composite component includes a turbomachine component.

10. The method of claim 1, wherein the coupon includes the metal alloy or a distinct metal alloy from the metal alloy of the metal alloy component.

11. The method of claim 1, further comprising performing a hot isostatic pressure (HIP) heat treatment (HT) on the composite component after the brazing.

12. A composite component comprising:

a metal alloy component including a main body, the main body having;

a wall having an inner surface and an outer surface; and

a slot extending at least partially through the wall, the slot including an angled main body interface in the wall;

a coupon coupled with the slot, the coupon having an angled coupon interface complementing the angled main body interface, wherein the coupon has a larger diameter (LD) spanning the slot across the outer surface of the main body; and

a smaller diameter (SD) spanning the slot across an inner surface of the main body, wherein the LD is defined by;

LD=((2*Z)/tan α

)+SD

wherein Z=a thickness of the wall and α

=an angle of the angled main body interface and the angled coupon interface, as measured from a plane coincident with the outer surface of the main body; and

a braze joint coupling the coupon to the main body at the slot.

13. The composite component of claim 12, wherein the metal alloy component includes a high-gamma prime alloy or a brittle alloy including:

René

125, René

80, René

N5, René

N4, René

108, GTD-111, GTD-444, Inconel (IN) 738, IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4, PWA1480, PWA1483, or PWA1484.

14. The composite component of claim 12, wherein the angle a is between approximately 10 degrees and approximately 45 degrees, as measured from the plane coincident with the outer surface of the main body.

15. The composite component of claim 12, wherein the angle a is between approximately 10 degrees and approximately 25 degrees, as measured from the plane coincident with the outer surface of the main body.

16. The composite component of claim 12, wherein the angled main body interface and the angled coupon interface are configured to bear a predominately shear stress in response to application of tension on the composite component.

17. The composite component of claim 12, wherein the composite component includes a turbomachine component.

18. The composite component of claim 12, wherein the coupon includes the metal alloy or a distinct metal alloy from the metal alloy of the metal alloy component.

19. A non-transitory computer readable storage medium storing code representative of at least a portion of a composite component, the at least a portion of the composite component physically generated upon execution of the code by a computerized additive manufacturing system, the code comprising:

code representing at least the portion of the composite component, the composite component including;

a metal alloy component including a main body, the main body having;

a wall having an inner surface and an outer surface; and

a slot extending at least partially through the wall, the slot including an angled main body interface in the wall;

a coupon coupled with the slot, the coupon having an angled coupon interface complementing the angled main body interface, wherein the coupon has a larger diameter (LD) spanning the slot across the outer surface of the main body; and

a smaller diameter (SD) spanning the slot across an inner surface of the main body, wherein the LD is defined by;

LD=((2*Z)/tan α

)+SD

wherein Z=a thickness of the wall and α

=an angle of the angled main body interface and the angled coupon interface, as measured from a plane coincident with the outer surface of the main body; and

a braze joint coupling the coupon to the main body at the slot.

20. The storage medium of claim 19, wherein in the case that the code represents the coupon, the computerized additive manufacturing system physically generates the coupon upon execution of the code, or wherein in the case that the code represents the metal alloy component, the computerized additive manufacturing system physically generates the metal alloy component upon execution of the code.