Method for providing turbulation on the inner surface of holes in an article, and related articles

Abstract

A method of providing turbulation on the inner surface of a passage hole (e.g., a turbine cooling hole) is described. The turbulation is first applied to a substrate which can eventually be inserted into the passage hole. The substrate is often a bar or tube, formed of a sacrificial material. After the turbulation is applied to the substrate, the substrate is inserted into the passage hole. The turbulation material is then fused to the inner surface, using a conventional heating technique. The sacrificial substrate can then be removed from the hole by various techniques. Related articles are also described.

1 . A method of providing turbulation on the inner surface of a passage hole, comprising the following steps: 
 (a) applying turbulation material to a substrate which is capable of being inserted into the passage hole and being fused to the inner surface of the passage hole;    (b) inserting the substrate into the passage hole, so that the substrate is adjacent to the inner surface of the passage hole; and    (c) fusing the turbulation material to the inner surface of the passage hole.    
   
   
       2 . The method of  claim 1 , wherein the turbulation material comprises a metal alloy.  
   
   
       3 . The method of  claim 2 , wherein the metal alloy comprises at least one element selected from the group consisting of nickel, cobalt, aluminum, chromium, silicon, iron, and copper.  
   
   
       4 . The method of  claim 2 , wherein the metal alloy comprises MCrAl(X), and M is an element selected from the group consisting of Ni, Co, Fe, and combinations thereof; and X is an element selected from the group consisting of Y, Ta, Si, Hf, Ti, Zr, B, C, and combinations thereof.  
   
   
       5 . The method of  claim 1 , wherein the substrate is a bar.  
   
   
       6 . The method of  claim 5 , wherein a bonding agent is also applied to the bar.  
   
   
       7 . The method of  claim 6 , wherein the bonding agent comprises a braze alloy.  
   
   
       8 . The method of  claim 7 , wherein the braze alloy comprises at least one metal selected from the group consisting of nickel, cobalt, iron, a precious metal, and a mixture which includes at least one of the foregoing.  
   
   
       9 . The method of  claim 8 , wherein the braze alloy comprises at least about 40% by weight nickel, and at least one additional element selected from the group consisting of silicon, chromium, boron, and iron.  
   
   
       10 . The method of  claim 6 , wherein the bonding agent is in the form of a sheet.  
   
   
       11 . The method of  claim 10 , wherein the sheet comprises a green braze tape.  
   
   
       12 . The method of  claim 10 , wherein the sheet comprises a metal foil.  
   
   
       13 . The method of  claim 6 , wherein the turbulation material comprises a particulate phase of discrete metal alloy particles, having an average particle size within a range of about 125 microns to about 4000 microns.  
   
   
       14 . The method of  claim 6 , wherein the turbulation material is applied directly to the surface of the bar, prior to the application of the bonding agent.  
   
   
       15 . The method of  claim 14 , wherein a binder material is used to provide temporary adhesion of the turbulation to the bar.  
   
   
       16 . The method of  claim 14 , wherein the turbulation material and the binder are in the form of a slurry which is applied directly to the surface of the bar.  
   
   
       17 . The method of  claim 14 , wherein the bonding agent is applied in the form of a layer over the turbulation material.  
   
   
       18 . The method of  claim 17 , wherein the layer of bonding agent is wrapped around the bar, so as to cover the discrete metal alloy particles.  
   
   
       19 . The method of  claim 18 , wherein the bonding agent comprises a braze alloy.  
   
   
       20 . The method of  claim 18 , wherein the bar is cylindrical.  
   
   
       21 . The method of  claim 18 , wherein the bar comprises a sacrificial material which is removed from the passage hole, after the turbulation material is fused to the inner surface of the passage hole.  
   
   
       22 . The method of  claim 21 , wherein the sacrificial material is selected from the group consisting of metal oxides, metal salts, metal halides, metal borates, metal sulfates, metal aluminates, carbon-based materials, and combinations thereof.  
   
   
       23 . The method of  claim 21 , wherein the sacrificial material is removed from the passage hole by a technique selected from the group consisting of aqueous washing; chemical leaching, vacuum extraction, etching, ultrasonic processes, combustion, and combinations of these techniques.  
   
   
       24 . The method of  claim 5 , wherein the surface of the bar contains a pattern of indentations, and each indentation has a dimension which is reciprocal to the dimension of a corresponding, desired turbulation site on the inner surface of the passage hole.  
   
   
       25 . The method of  claim 24 , wherein the indentations are filled with a composition comprising a bonding agent and the turbulation material, prior to insertion of the bar into the passage hole.  
   
   
       26 . The method of  claim 25 , wherein the composition further comprises a binder.  
   
   
       27 . The method of  claim 25 , wherein the bonding agent is a braze material.  
   
   
       28 . The method of  claim 27 , wherein the braze material comprises at least one metal selected from the group consisting of nickel, cobalt, iron, a precious metal, and a mixture which includes at least one of the foregoing.  
   
   
       29 . The method of  claim 27 , wherein at least one layer of braze tape is wrapped around the bar after the indentations are filled with the composition, and prior to insertion of the bar in the passage hole.  
   
   
       30 . The method of  claim 24 , wherein the bar comprises a sacrificial material which is removed from the passage hole, after the turbulation material is fused to the inner surface of the passage hole.  
   
   
       31 . The method of  claim 5 , wherein the turbulation material is combined with a bonding agent to form multiple rings of a turbulation-bonding agent composition, prior to step (b); and the rings are then inserted over the bar, so that the bar is encircled by the rings; wherein the rings are spaced from each other in a pre-selected pattern which defines the desired pattern of turbulation for the surface of the passage hole.  
   
   
       32 . The method of  claim 31 , wherein, prior to step (b), sacrificial rings comprising a sacrificial material are inserted over the bar intermittently with the insertion of the turbulation-bonding agent rings, so as to fill spaces which exist between the rings of the turbulation-bonding agent, thereby maintaining a desired separation between the turbulation-bonding agent rings.  
   
   
       33 . The method of  claim 32 , wherein the bar is removed after being inserted into the passage hole, while the turbulation-bonding agent rings and sacrificial rings remain in place within the passage hole.  
   
   
       34 . The method of  claim 33 , wherein the sacrificial rings are removed from the passage hole after the turbulation material is fused to the inner surface of the passage hole.  
   
   
       35 . The method of  claim 34 , wherein the sacrificial rings are removed by a technique selected from the group consisting of aqueous washing; chemical leaching, vacuum extraction, etching, ultrasonic processes, combustion, and combinations of these techniques.  
   
   
       36 . The method of  claim 31 , wherein the bonding agent is a braze composition.  
   
   
       37 . The method of  claim 5 , wherein the bar is a tube which comprises a metal foil, having a first surface and an opposite, second surface.  
   
   
       38 . The method of  claim 37 , wherein the metal foil has a surface area sufficient to cover a portion of the inner surface of the passage hole on which turbulation is desired.  
   
   
       39 . The method of  claim 37 , wherein the metal foil comprises a braze material, and the turbulation material is provided on the first surface of the metal foil.  
   
   
       40 . The method of  claim 39 , wherein the metal foil is rolled into a shape substantially similar to the shape of the passage hole, and is inserted into the passage hole, so that the second surface is adjacent to or in contact with the inner surface of the passage hole, and the turbulation on the first surface of the metal foil becomes attached to the surface of the passage hole, after the fusing step.  
   
   
       41 . The method of  claim 40 , wherein the foil is temporarily held in place within the passage hole by a fastening technique, prior to the fusing step.  
   
   
       42 . A method of providing turbulation on the inner surface of at least one radial cooling hole in a turbine blade formed of a superalloy material, comprising the following steps: 
 (i) applying turbulation material to a cylindrical bar formed of a sacrificial material, said bar being capable of being fused to the inner surface of the hole;    (ii) wrapping a layer of braze material around the bar, covering the turbulation material;    (iii) inserting the bar into the hole;    (iv) applying sufficient heat to braze the turbulation material to the inner surface of the hole with the braze material; and then    (v) removing the cylindrical bar by a technique suitable for eliminating the sacrificial material.    
   
   
       43 . An article, comprising: 
 (I) a substrate containing at least one passage hole, wherein the passage hole includes an inner surface; and    (II) turbulation material bonded to at least a portion of the inner surface of the passage hole by a bonding agent.    
   
   
       44 . The article of  claim 43 , wherein the turbulation material extends beyond the inner surface of the passage hole, forming a plurality of protuberances.  
   
   
       45 . The article of  claim 44 , wherein the protuberances are disposed in a selected pattern.  
   
   
       46 . The article of  claim 44 , wherein the bonding agent comprises a braze alloy.  
   
   
       47 . The article of  claim 44 , wherein the turbulation material comprises a metal alloy.  
   
   
       48 . The article of  claim 47 , wherein the metal alloy comprises at least one element selected from the group consisting of nickel, cobalt, aluminum, chromium, silicon, iron, and copper.  
   
   
       49 . The article of  claim 44 , wherein the substrate comprises a superalloy material.  
   
   
       50 . The article of  claim 44 , wherein the substrate is a turbine engine component.