Method of Making a Combustion Turbine Component from Metallic Combustion Turbine Subcomponent Greenbodies

Abstract

A method of making a combustion turbine component includes assembling a plurality of metallic combustion turbine subcomponent greenbodies together to form a metallic greenbody assembly and sintering the metallic greenbody assembly to thereby form the combustion turbine component. Each of the plurality of metallic combustion turbine subcomponent greenbodies may be formed by direct metal fabrication (DMF). In addition, each of plurality of metallic combustion turbine subcomponent greenbodies may include an activatable binder and the activatable binder may be activated prior to sintering.

1 . A method of making a combustion turbine component comprising:
 assembling a plurality of metallic combustion turbine subcomponent greenbodies together to form a metallic greenbody assembly; and   sintering the metallic greenbody assembly to thereby form the combustion turbine component.   
     
     
         2 . The method of  claim 1  further comprising forming each of the plurality of metallic combustion turbine subcomponent greenbodies by direct metal fabrication (DMF). 
     
     
         3 . The method of  claim 2  wherein the DMF comprises tomo lithographic molding. 
     
     
         4 . The method of  claim 2  wherein the DMF comprises metal injection molding. 
     
     
         5 . The method of  claim 1  wherein each of the plurality of metallic combustion turbine subcomponent greenbodies comprises an activatable binder; and further comprising activating the activatable binder prior to sintering. 
     
     
         6 . The method of  claim 1  further comprising positioning an activatable binder between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies; and further comprising activating the activatable binder prior to sintering. 
     
     
         7 . The method of  claim 1  wherein the combustion turbine component is devoid of interfaces between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies after sintering. 
     
     
         8 . The method of  claim 1  wherein the combustion turbine component has interfaces between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies after sintering. 
     
     
         9 . The method of  claim 1  wherein each of the plurality of metallic combustion turbine subcomponent greenbodies comprises at least one of an oxide dispersion strengthened (ODS) alloy, an intermetallic compound, and a refractory metal. 
     
     
         10 . The method of  claim 1  wherein forming each of the plurality of metallic combustion turbine subcomponent greenbodies comprises forming at least one thereof to have a plurality of surface features each with a dimension less than 200 μm. 
     
     
         11 . A method of making a combustion turbine component comprising:
 forming a plurality of metallic combustion turbine subcomponent greenbodies by direct metal fabrication (DMF), each of the plurality of metallic combustion turbine subcomponent greenbodies comprising an activatable binder;   assembling the plurality of metallic combustion turbine subcomponent greenbodies together to form a metallic greenbody assembly;   activating the activatable binder; and   sintering the metallic greenbody assembly to thereby form the combustion turbine component.   
     
     
         12 . The method of  claim 11  wherein the DMF comprises tomo lithographic molding. 
     
     
         13 . The method of  claim 11  wherein the DMF comprises metal injection molding. 
     
     
         14 . The method of  claim 11  wherein the combustion turbine component is devoid of interfaces between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies after sintering. 
     
     
         15 . The method of  claim 11  wherein the combustion turbine component has interfaces between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies after sintering. 
     
     
         16 . The method of  claim 11  wherein each of the plurality of metallic combustion turbine subcomponent greenbodies comprises at least one of an oxide dispersion strengthened (ODS) alloy, an intermetallic compound, and a refractory metal. 
     
     
         17 . The method of  claim 11  wherein forming each of the plurality of metallic combustion turbine subcomponent greenbodies comprises forming at least one thereof to have a plurality of surface features each with a dimension less than 200 μm. 
     
     
         18 . A method of making a combustion turbine component comprising:
 forming a plurality of metallic combustion turbine subcomponent greenbodies by direct metal fabrication (DMF);   assembling the plurality of metallic combustion turbine subcomponent greenbodies together and positioning an activatable binder between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies to form a metallic greenbody assembly;   activating the activatable binder; and   sintering the metallic greenbody assembly to thereby form the combustion turbine component.   
     
     
         19 . The method of  claim 18  wherein the DMF comprises one of tomo lithographic molding and metal injection molding. 
     
     
         20 . The method of  claim 18  wherein the combustion turbine component is devoid of interfaces between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies after sintering. 
     
     
         21 . The method of  claim 18  wherein the combustion turbine component has interfaces between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies after sintering. 
     
     
         22 . The method of  claim 18  wherein each of the plurality of metallic combustion turbine subcomponent greenbodies comprises at least one of an oxide dispersion strengthened (ODS) alloy, an intermetallic compound, and a refractory metal. 
     
     
         23 . The method of  claim 18  wherein forming each of the plurality of metallic combustion turbine subcomponent greenbodies comprises forming at least one thereof to have a plurality of surface features each with a dimension less than 200 μm.