Method of fabricating a component and a manufactured component

Abstract

A method of fabricating a component and a fabricated component are disclosed. The method includes depositing a material to a component and manipulating the material to form a boundary region and a filler region for desired properties. The component includes the boundary region and the filler region, thereby having the desired properties.

What is needed is: 
     
         1 . A welded component, comprising:
 a boundary region positioned at least partially on a crack sensitive fusion boundary; and   a filler region positioned at least partially on the boundary region;   wherein the boundary region provides resistance to strain age cracking within the crack sensitive fusion boundary.   
     
     
         2 . The component of  claim 1 , wherein one or more of the boundary region and the filler region includes a nickel-based superalloy having a composition, by weight, of about 14% chromium, about 9.5% cobalt, about 3.8% tungsten, about 1.5% molybdenum, about 4.9% titanium, about 3.0% aluminum, about 0.1% carbon, about 0.01% boron, about 2.8% tantalum, and a balance of nickel. 
     
     
         3 . The component of  claim 1 , wherein one or more of the boundary region and the filler region includes a nickel-based superalloy having a composition, by weight, of about 9.75% chromium, about 7.5% cobalt, about 3.5% titanium, about 4.2% aluminum, about 6.0% tungsten, about 1.5% molybdenum, about 4.8% tantalum, about 0.08% carbon, about 0.009% zirconium, about 0.009% boron, and a balance of nickel. 
     
     
         4 . The component of  claim 1 , wherein one or more of the boundary region and the filler region includes a nickel-based superalloy having a composition, by weight, of about 7.5% cobalt, about 7.0% chromium, about 6.5% tantalum, about 6.2% aluminum, about 5.0% tungsten, about 3.0% rhenium, about 1.5% molybdenum, about 0.15% hafnium, about 0.05% carbon, about 0.004% boron, about 0.01% yttrium, and a balance of nickel. 
     
     
         5 . The component of  claim 1 , wherein one or more of the boundary region and the filler region includes a nickel-based superalloy having a composition, by weight, of about 9.75% chromium, about 7.5% cobalt, about 4.2% aluminum, about 3.5% titanium, about 1.5% molybdenum, about 6.0% tungsten, about 4.8% tantalum, about 0.5% niobium, about 0.15% hafnium, about 0.05% carbon, about 0.004% boron, and a balance of nickel. 
     
     
         6 . The component of  claim 1 , wherein one or more of the boundary region and the filler region includes a nickel-based superalloy having a composition, by weight, of about 9.5% cobalt, about 8.0% chromium, about 9.5% tungsten, about 0.5% molybdenum, about 5.5% aluminum, about 0.8% titanium, about 3.0% tantalum, about 0.1% zirconium, about 1.0% carbon, about 0.15% hafnium and a balance of nickel. 
     
     
         7 . The component of  claim 1 , wherein a material of the boundary region includes substantially the same composition as a material of the filler region. 
     
     
         8 . The component of  claim 1 , wherein a material of the boundary region includes a different composition from the a material of the filler region. 
     
     
         9 . The component of  claim 1 , wherein the filler region comprises a first filler material and a second filler material. 
     
     
         10 . The component of  claim 1 , further comprising a surface layer over the filler region. 
     
     
         11 . The component of  claim 10 , wherein the surface layer includes a composition that differs from at least one of a boundary material composition and a filler material composition. 
     
     
         12 . The component of  claim 1 , wherein the boundary region covers the entire crack sensitive fusion boundary. 
     
     
         13 . The component of  claim 1 , wherein the boundary region fills about ⅓ of the volume of a cavity in the component. 
     
     
         14 . The component of  claim 1 , wherein one or more of the boundary region and the filler region includes a nickel-based superalloy selected from the group consisting of:
 a composition, by weight, of about 15% chromium, about 10% cobalt, about 4% tungsten, about 2% molybdenum, about 5% titanium, about 3.% aluminum, and about 0.1% carbon, about 0.01% boron, about 3% tantalum, and a balance of nickel;   a composition, by weight, of about 10% chromium, about 8% cobalt, about 4% titanium, about 5% aluminum, about 6% tungsten, about 1.5% molybdenum, about 5% tantalum, about 0.08% carbon, about 0.009% zirconium, about 0.009% boron, and a balance of nickel;   a composition, by weight, of about 8% cobalt, about 7% chromium, about 6% tantalum, about 7% aluminum, about 5% tungsten, about 3% rhenium, about 2% molybdenum, about 0.15% hafnium, about 0.05% carbon, about 0.004% boron, about 0.01% yttrium, and a balance of nickel; and   a composition, by weight, of about 10% chromium, about 8% cobalt, about 5% aluminum, about 4% titanium, about 2% molybdenum, about 6% tungsten, about 5% tantalum, about 0.5% niobium, about 0.15% hafnium, about 0.05% carbon, about 0.004% boron, and a balance of nickel.   
     
     
         15 . A welded component, comprising:
 a base metal having a crack sensitive fusion boundary;   a boundary region positioned at least partially on the crack sensitive fusion boundary; and   a filler region positioned at least partially on the boundary region;   wherein the boundary region provides resistance to strain age cracking within the crack sensitive fusion boundary.   
     
     
         16 . The component of  claim 15 , wherein the crack sensitive fusion boundary is within a cavity of the base metal. 
     
     
         17 . The component of  claim 16 , wherein the cavity of the base metal includes a geometry selected from the group consisting of a triangle, a semicircle, a semisphere, a curved geometry, a channel, a rectilinear geometry, and a complex geometry. 
     
     
         18 . The component of  claim 15 , wherein at least one of the boundary region and the filler region include a material having a composition that differs from a base metal material of the base metal. 
     
     
         19 . A welded component, comprising:
 a boundary region positioned at least partially on a crack sensitive fusion boundary, the boundary region comprising a boundary material;   a filler region positioned at least partially on the boundary region, the filler region comprising a first filler material and a second filler material; and   a surface layer over the filler region;   wherein the boundary region provides resistance to strain age cracking within the crack sensitive fusion boundary.   
     
     
         20 . The component of  claim 19 , wherein the second filler material differs from at least one of the boundary material and the first filler material.