Additively deposited gas turbine engine cooling component

Abstract

An example gas turbine engine component includes a component configured to separate a cooling air plenum from a heated gas environment. The component includes a substrate defining a surface, and a unitary structure. The unitary structure includes a cooling region and a cover layer. The cover layer defines a hot wall surface configured to face the heated gas environment. The cooling region is disposed between the cover surface and the substrate and includes a plurality of support structures extending between the cover layer and the surface of the substrate. At least some of the support structures define a respective bond surface bonded to the substrate at the surface of the substrate. An example technique for fabricating the gas turbine engine component includes additively depositing the unitary structure on the surface of the substrate.

What is claimed is: 
     
         1 . A gas turbine engine component configured to separate a cooling air plenum from a heated gas environment, the gas turbine engine component comprising:
 a substrate defining a surface; and   a unitary structure comprising a cooling region and a cover layer, wherein:
 the cover layer defines a hot wall surface configured to face the heated gas environment, 
 the cooling region is disposed between the cover layer and the substrate and comprises a plurality of support structures extending between the cover layer and the surface of the substrate, and 
 at least some of the support structures define a respective bond surface bonded to the substrate at the surface of the substrate. 
   
     
     
         2 . The gas turbine engine component of  claim 1 , wherein the plurality of support structures defines a plurality of cooling channels, respective cooling channels of the plurality of cooling channels being between adjacent support structures of the plurality of support structures. 
     
     
         3 . The gas turbine engine component of  claim 2 , wherein the hot wall surface defines a plurality of cooling apertures, wherein respective cooling apertures of the plurality of cooling apertures are fluidly connected to respective cooling channels of the plurality of cooling channels for fluidly connecting the heated gas environment to the cooling region. 
     
     
         4 . The gas turbine engine component of  claim 1 , wherein the unitary component comprises a turbine vane defining an exterior surface comprising the hot wall surface and defining an internal hollow chamber comprising the cooling air plenum, wherein the cover layer comprises a coversheet, and wherein the substrate comprises a spar. 
     
     
         5 . The gas turbine engine component of  claim 1 , wherein the unitary component comprises a combustor component configured to separate the cooling air plenum from a combustion chamber comprising the heated gas environment. 
     
     
         6 . The gas turbine engine component of  claim 1 , wherein the unitary component comprises a dual wall structure configured to separate the cooling air plenum from the heated gas environment, wherein the dual wall structure defines a hot section wall comprising the hot wall surface, wherein the substrate defines a cold section wall, wherein the cold section wall defines a plurality of impingement apertures that extend through a thickness of the cold section wall, wherein the plurality of support structures comprises a plurality of pedestals that connect the cold section wall to the hot section wall to define a plurality of cooling channels between the cold section wall and the hot section wall, and wherein the plurality of impingement apertures, the plurality of cooling channels, and the cooling apertures fluidly connect the cooling air plenum to the heated gas environment. 
     
     
         7 . The gas turbine engine component of  claim 1 , wherein the unitary component comprises a flame tube, a combustion ring, a combustor casing, a combustor guide vane, a turbine vane, a turbine disc, or a turbine blade. 
     
     
         8 . A method of fabricating a gas turbine engine component configured to separate a cooling air plenum from a heated gas environment, the method comprising:
 additively depositing a unitary structure on a surface of a substrate, wherein the unitary structure comprises a cooling region and a cover layer, wherein the cover layer defines a hot wall surface configured to face the heated gas environment, wherein the cooling region is disposed between the cover layer and the substrate and comprises a plurality of support structures extending between the cover layer and the surface of the substrate, and wherein at least some of the support structures define a respective bond surface bonded to the substrate at the surface of the substrate.   
     
     
         9 . The method of  claim 8 , wherein the plurality of support structures defines a plurality of cooling channels, respective cooling channels of the plurality of cooling channels being between adjacent support structures of the plurality of support structures. 
     
     
         10 . The method of  claim 8 , further comprising installing the unitary structure in a gas turbine engine. 
     
     
         11 . The method of  claim 10 , wherein installing the unitary structure comprises bonding the gas turbine engine component to a gas turbine engine surface. 
     
     
         12 . The method of  claim 11 , wherein the bonding comprises diffusion bonding. 
     
     
         13 . The method of  claim 10 , wherein the installing the unitary structure comprises connecting the gas turbine engine component to an air-cooling system of the gas turbine engine. 
     
     
         14 . The method of  claim 8 , wherein the unitary structure comprises a dual wall component. 
     
     
         15 . The method of  claim 8 , wherein the unitary structure comprises a flame tube, a combustion ring, a combustor casing, a combustor guide vane, a turbine vane, a turbine disc, or a turbine blade. 
     
     
         16 . The method of  claim 9 , wherein the hot wall surface defines a plurality of cooling apertures fluidly connected to the plurality of support structures, wherein respective cooling apertures of the plurality of cooling apertures are fluidly connected to respective cooling channels of the plurality of cooling channels for fluidly connecting the heated gas environment to the cooling region. 
     
     
         17 . The method of  claim 8 , wherein additively depositing the unitary structure comprises:
 directing a material stream and an energy stream at a focal region on the surface of the substrate, and   moving the focal region along a predetermined path.   
     
     
         18 . The method of  claim 17 , wherein the energy beam comprises a laser beam and wherein the material stream comprises one or more of metal or alloy powder, wire, or ribbon.