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.

What is claimed is: 
     
         1 . A method comprising:
 liquid state sintering a metallic greenbody assembly to form a combustion turbine component;   wherein:
 the metallic greenbody assembly comprises a plurality of metallic combustion turbine subcomponent greenbodies and a binder; 
 the binder located between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies; 
 the binder comprising a metallic mix and a melting point depressor; 
 the binder activatable to cause liquid phase bonding between the plurality of metallic combustion turbine subcomponent greenbodies; 
 at least one metallic combustion turbine subcomponent greenbody from the plurality of metallic combustion turbine subcomponent greenbodies was formed via tomo lithographic molding; and 
 at least one metallic combustion turbine subcomponent greenbody from the plurality of metallic combustion turbine subcomponent greenbodies was formed via a direct metal fabrication process selected from a layered powder buildup, selective laser sintering, stereolithography, deposition, solid ground curing, laminated object manufacturing, fused deposition, and ballistic particle manufacturing. 
   
     
     
         2 . The method of  claim 1 , further comprising:
 forming at least one metallic combustion turbine subcomponent greenbody from the plurality of metallic combustion turbine subcomponent greenbodies.   
     
     
         3 . The method of  claim 1 , further comprising:
 assembling the plurality of metallic combustion turbine subcomponent greenbodies to form the metallic greenbody assembly.   
     
     
         4 . The method of  claim 1 , further comprising:
 prior to said sintering, activating the binder.   
     
     
         5 . The method of  claim 1 , further comprising:
 positioning the binder between the adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies.   
     
     
         6 . The method of  claim 1 , wherein:
 each of the plurality of metallic combustion turbine subcomponent greenbodies comprises the binder   
     
     
         7 . The method of  claim 1 , wherein:
 after said sintering, the combustion turbine component is devoid of interfaces between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies.   
     
     
         8 . The method of  claim 1 , wherein:
 after said sintering, the combustion turbine component has interfaces between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies.   
     
     
         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:
 a metallic combustion turbine subcomponent greenbody from the plurality of metallic combustion turbine subcomponent greenbodies comprises an oxide dispersion strengthened (ODS) alloy.   
     
     
         11 . The method of  claim 1 , wherein:
 a metallic combustion turbine subcomponent greenbody from the plurality of metallic combustion turbine subcomponent greenbodies comprises an intermetallic compound.   
     
     
         12 . The method of  claim 1 , wherein:
 a metallic combustion turbine subcomponent greenbody from the plurality of metallic combustion turbine subcomponent greenbodies comprises a refractory metal.   
     
     
         13 . The method of  claim 1 , wherein:
 at least one metallic combustion turbine subcomponent greenbody from the plurality of metallic combustion turbine subcomponent greenbodies has a plurality of surface features each with a dimension less than 200 μm.   
     
     
         14 . The method of  claim 1 , wherein:
 the direct metal fabrication process comprises a layered powder buildup process.   
     
     
         15 . The method of  claim 1 , wherein:
 the direct metal fabrication process comprises selective laser sintering.   
     
     
         16 . The method of  claim 1 , wherein:
 the direct metal fabrication process comprises stereolithography.   
     
     
         17 . The method of  claim 1 , wherein:
 the direct metal fabrication process comprises a deposition technique.   
     
     
         18 . The method of  claim 1 , wherein:
 the direct metal fabrication process comprises solid ground curing.   
     
     
         19 . The method of  claim 1 , wherein:
 the direct metal fabrication process comprises laminated object manufacturing.   
     
     
         20 . The method of  claim 1 , wherein:
 the direct metal fabrication process comprises fused deposition modeling.   
     
     
         21 . The method of  claim 1 , wherein:
 the direct metal fabrication process comprises ballistic particle manufacturing.   
     
     
         22 . A method comprising:
 assembling a plurality of metallic combustion turbine subcomponent greenbodies and a binder to form a metallic greenbody assembly;   positioning the binder between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies;   activating the binder; and   sintering the metallic greenbody assembly to form a combustion turbine component;   wherein:
 the binder located between adjacent ones of the plurality of metallic combustion turbine subcomponent greenbodies; 
 the binder comprising a metallic mix and a melting point depressor; 
 the binder activatable to cause liquid phase bonding between the plurality of metallic combustion turbine subcomponent greenbodies; 
 at least one metallic combustion turbine subcomponent greenbody from the plurality of metallic combustion turbine subcomponent greenbodies was formed via tomo lithographic molding; and 
 at least one metallic combustion turbine subcomponent greenbody from the plurality of metallic combustion turbine subcomponent greenbodies was formed via a direct metal fabrication process selected from a layered powder buildup, selective laser sintering, stereolithography, deposition, solid ground curing, laminated object manufacturing, fused deposition, and ballistic particle manufacturing.