Article, turbine component and airfoil treatment methods

Abstract

An article treatment method is disclosed including removing an affected area from an article, the article including the affected area and a substrate composed of a substrate material, forming an unaffected surface. A structural material is applied to the unaffected surface by cold spraying a plurality of particles of the structural material from a cold spray apparatus. The structural material and the article are finished, forming a treated article including an unused article conformation. A turbine component treatment method is disclosed for a turbine component including a hard-to-weld (HTW) alloy, wherein applying the structural material includes impacting the plurality of particles, and plastically deforming the plurality of particles to form a mechanical bond between the structural material and the HTW alloy. An airfoil treatment method is disclosed further including the cold spraying forming a near net shape of an unused airfoil composition.

1 . An article treatment method, consisting of:
 removing an affected area from an article, the article including the affected area and a substrate composed of a substrate material, the removing forming an unaffected surface;   applying a structural material to the unaffected surface by cold spraying a plurality of particles of the structural material from a cold spray apparatus; and   finishing the structural material and the article, the finishing forming a treated article including an unused article conformation,   wherein the finishing consists of applying a finishing technique selected from the group consisting of grinding, polishing, peening, heat treating, diffusing the structural material into the substrate material to form a chemical bond, and combinations thereof.   
     
     
         2 . The method of  claim 1 , wherein cold spraying the plurality of particles includes supersonic laser deposition of the plurality of particles. 
     
     
         3 . The method of  claim 1 , wherein cold spraying the plurality of particles includes impacting the plurality of particles, plastically deforming the plurality of particles to form a mechanical bond between the structural material and the substrate material. 
     
     
         4 . The method of  claim 1 , wherein providing the article includes providing a hard-to-weld (HTW) alloy as the substrate material. 
     
     
         5 . The method of  claim 1 , wherein providing the article includes providing a turbine component as the article. 
     
     
         6 . The method of  claim 5 , wherein providing the turbine component includes providing a turbine component selected from the group consisting of at least one of an airfoil, a nozzle (also known as a vane), a bucket (also known as a blade), a shroud, a combustion fuel nozzle, a 3d-manufactured component, a hot gas path component, a combustor, a combustion transition piece, a combustion liner, a seal, a rotating component, a wheel, and a disk. 
     
     
         7 . The method of  claim 1 , wherein applying the structural material includes forming a near net shape of the unused article conformation. 
     
     
         8 . The method of  claim 1 , wherein removing the affected area includes removing surface oxides. 
     
     
         9 . The method of  claim 8 , wherein removing the affected area includes a process selected from the group consisting of mechanically abrading the affected area, chemically etching the affected area, thermally cleaning the affected area under vacuum, and combinations thereof. 
     
     
         10 . The method of  claim 1 , wherein applying the structural material includes applying the structural material having an average particle size less than about 100 μm. 
     
     
         11 . The method of  claim 1 , wherein applying the structural material includes applying the substrate material as the structural material. 
     
     
         12 . The method of  claim 1 , wherein applying the structural material includes applying a complementary material compositionally distinct from the substrate material. 
     
     
         13 . The method of  claim 1 , wherein applying the structural material includes applying a first structural material and applying a second structural material, the first structural material being compositionally distinct from the second structural material. 
     
     
         14 . (canceled) 
     
     
         15 . A turbine component treatment method, consisting of:
 removing an affected area from a turbine component, the turbine component including the affected area and a substrate composed of a hard-to-weld (HTW) alloy, the removing forming an unaffected surface and the removing including a process selected from the group consisting of mechanically abrading the affected area, chemically etching the affected area, thermally cleaning the affected area under vacuum, and combinations thereof;   applying a structural material to the unaffected surface by cold spraying a plurality of particles of the structural material from a cold spray apparatus, impacting the plurality of particles, and plastically deforming the plurality of particles to form a mechanical bond between the structural material and the HTW alloy; and   finishing the structural material and the turbine component, the finishing forming a treated turbine component and the finishing consisting of applying a finishing technique selected from the group consisting of grinding, polishing, peening, heat treating, diffusing the structural material into the substrate material to form a chemical bond, and combinations thereof, the treated turbine component including an unused turbine component conformation.   
     
     
         16 . The method of  claim 15 , wherein applying the structural material includes forming a near net shape of the unused turbine component conformation. 
     
     
         17 . The method of  claim 15 , wherein applying the structural material includes applying the structural material having an average particle size less than about 100 μm. 
     
     
         18 . The method of  claim 15 , wherein applying the structural material includes applying the substrate material as the structural material. 
     
     
         19 . The method of  claim 15 , wherein applying the structural material includes applying a complementary material compositionally distinct from the substrate material. 
     
     
         20 . An airfoil treatment method, consisting of:
 removing an affected area from an airfoil, the airfoil including the affected area and a substrate composed of a hard-to-weld (HTW) alloy, the removing forming an unaffected surface and the removing including a process selected from the group consisting of mechanically abrading the affected area, chemically etching the affected area, thermally cleaning the affected area under vacuum, and combinations thereof;   applying a structural material to the unaffected surface by cold spraying a plurality of particles of the structural material from a cold spray apparatus, impacting the plurality of particles, and plastically deforming the plurality of particles to form a mechanical bond between the structural material and the HTW alloy, forming a near net shape of an unused airfoil conformation; and   finishing the structural material and the airfoil, the finishing forming a treated airfoil and the finishing consisting of applying a finishing technique selected from the group consisting of grinding, polishing, peening, heat treating, diffusing the structural material into the substrate material to form a chemical bond, and combinations thereof, the treated airfoil including the unused airfoil conformation,   wherein the unused airfoil conformation includes a planar airfoil tip.