Method of Making a Combustion Turbine Component Having a Plurality of Surface Cooling Features and Associated Components

Abstract

A method of making a combustion turbine component includes forming a metallic body by direct metal fabrication (DMF) to have at least one surface portion defining a first plurality of surface cooling features each having a first dimension and at least one second surface cooling feature on at least one of the first plurality of surface cooling features and having a second dimension less than said first dimension and less than 200 μm. Forming the metallic body by DMF may include forming a plurality of metallic combustion turbine subcomponent greenbodies by DMF and assembling the plurality of metallic combustion turbine subcomponent greenbodies together to form a metallic greenbody assembly. The metallic greenbody assembly may be sintered to thereby form the metallic body.

1 . A method of making a combustion turbine component comprising:
 forming a metallic body by direct metal fabrication (DMF) to have   at least one surface portion defining a plurality of coarse surface cooling features each having a first dimension, and   at least one fine surface cooling feature on at least one of the plurality of coarse surface cooling features and having a second dimension less than said first dimension and less than 200 μm.   
     
     
         2 . The method of  claim 1  wherein the at least one fine surface cooling feature comprises a projection. 
     
     
         3 . The method of  claim 1  wherein the at least one fine surface cooling feature comprises a convex projection. 
     
     
         4 . The method of  claim 1  wherein the at least one fine surface cooling feature comprises a recess. 
     
     
         5 . The method of  claim 1  wherein the at least one fine surface cooling feature comprises a concave recess. 
     
     
         6 . The method of  claim 1  wherein the DMF comprises tomo lithographic molding. 
     
     
         7 . The method of  claim 1  wherein the DMF comprises metal injection molding. 
     
     
         8 . The method of  claim 1  wherein forming the metallic body by DMF comprises:
 forming a plurality of metallic combustion turbine subcomponent greenbodies by 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 metallic body. 
 
     
     
         9 . The method of  claim 1  wherein the first dimension is greater than 500 μm. 
     
     
         10 . The method of  claim 1  wherein at least one of the plurality of coarse surface cooling features comprises a projection. 
     
     
         11 . The method of  claim 1  wherein at least one of the plurality of coarse surface cooling features comprises a recess. 
     
     
         12 . The method of  claim 1  wherein the metallic combustion turbine component body comprises at least one of an oxide dispersion strengthened (ODS) alloy, an intermetallic compound, and a refractory metal. 
     
     
         13 . A method of making a combustion turbine component comprising:
 forming a plurality of metallic combustion turbine subcomponent greenbodies by DMF, at least one of the plurality of metallic combustion turbine subcomponent greenbodies being formed to have
 at least one surface portion defining a plurality of coarse surface cooling features each having a first dimension greater than 500 μm, and 
 at least one fine surface cooling feature on at least one of the plurality of coarse surface cooling features and having a second dimension less than 200 μm; 
   assembling the 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.   
     
     
         14 . The method of  claim 13  wherein the plurality of metallic combustion turbine subcomponent greenbodies comprises an activatable binder; and further comprising activating the activatable binder prior to sintering. 
     
     
         15 . The method of  claim 13  wherein the at least one fine surface cooling feature comprises a projection. 
     
     
         16 . The method of  claim 13  wherein the at least one fine surface cooling feature comprises a convex projection. 
     
     
         17 . The method of  claim 13  wherein the at least one fine surface cooling feature comprises a recess. 
     
     
         18 . The method of  claim 13  wherein the at least one fine surface cooling feature comprises a concave recess. 
     
     
         19 . The method of  claim 13  wherein the DMF comprises tomo lithographic molding. 
     
     
         20 . The method of  claim 13  wherein the DMF comprises metal injection molding. 
     
     
         21 . The method of  claim 13  wherein at least one of the plurality of coarse surface cooling features comprises a projection. 
     
     
         22 . The method of  claim 13  wherein at least one of the plurality of coarse surface cooling features comprises a recess. 
     
     
         23 . The method of  claim 13  wherein at least one 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. 
     
     
         24 . A combustion turbine component comprising:
 a metallic body to define at least a substrate for the combustion turbine component, said metallic body having
 at least one surface portion defining a plurality of coarse cooling features each having a first dimension, and 
 at least one fine cooling feature on at least one of said plurality of coarse cooling features each having a second dimension less than the first dimension and less than 200 μm. 
   
     
     
         25 . The combustion turbine component of  claim 24  wherein the first dimension is greater than 500 μm. 
     
     
         26 . The combustion turbine component of  claim 24  wherein the at least one fine surface cooling feature comprises a projection. 
     
     
         27 . The combustion turbine component of  claim 24  wherein the at least one fine surface cooling feature comprises a convex projection. 
     
     
         28 . The combustion turbine component of  claim 24  wherein the at least one fine surface cooling feature comprises a recess. 
     
     
         29 . The combustion turbine component of  claim 24  wherein the at least one fine surface cooling feature comprises a concave recess. 
     
     
         30 . The combustion turbine component of  claim 24  wherein at least one of the plurality of coarse surface cooling features comprises a projection. 
     
     
         31 . The combustion turbine component of  claim 24  wherein at least one of the plurality of coarse surface cooling features comprises a recess. 
     
     
         32 . The combustion turbine component of  claim 24  wherein the metallic combustion turbine component body comprises at least one of an oxide dispersion strengthened (ODS) alloy, an intermetallic compound, and a refractory metal.