Method of forming or repairing part with overhung section, and related turbomachine part

Abstract

To form or repair a part with an overhung section, and to provide a related turbomachine blade.SOLUTION: When forming or repairing a part with an overhung section, a portion is removed and a section is added to the portion. The section includes the overhung section. The adding includes sequentially layering at least a plurality of material layers onto the part, the at least plurality of material layers approximating dimensions of the section including the overhung section. The sequential layering may include, for example, laser welding, and may be carried out in a number of ways that create varied layers within the overhung section. The method may include machining the at least one plurality of material layers to form the section including the overhung section.SELECTED DRAWING: Figure 14

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to the manufacture and repair of parts, and more particularly to methods of forming or repairing turbomachine parts, such as turbomachine blades having overhangs. [Background technology]

[0002] Industrial parts may have sections that overhang from other parts of the part. Overhung sections may need to be added during formation or repaired after a period of use. One exemplary application includes flared tips of turbomachine blades, such as those available from General Electric Company (Schenectady, NY). Flared tip turbomachine blades include an airfoil having a pressure side and a suction side joined along leading and trailing edges. A flared tip is joined to a radially outer end of the airfoil and may extend circumferentially beyond the pressure side and / or suction side of the airfoil, i.e., relative to the axis of the turbomachine. Traditional non-flared turbomachinery blades require two-dimensional build-up of material, for example, using casting or additive manufacture, either vertically or radially. The manufacture of flare tip turbo blades involves adding material in both the circumferential and radial directions. Flare tip turbomachinery blades are currently not repairable and are therefore replaced. Other turbomachinery hot gas path components and other industrial components have overhangs and are in a similar situation. Summary of the Invention

[0003] One aspect of the disclosure provides a turbomachine component comprising a body having a first side, a second side, and a longitudinal axis, and an overhanging portion extending in an overhanging manner from at least one of the first side and the second side of the body, at least a portion of the overhanging portion including multiple layers of material, each layer of material extending at an acute angle relative to the longitudinal axis of the body.

[0004] Another aspect of the disclosure relates to a method for adding a section to a part, the section including an overhanging portion, the adding including sequentially depositing a plurality of layers of material over a surface of the part, the plurality of layers of material approximating dimensions of the section including the overhanging portion, the method including machining the plurality of layers of material to form the section including the overhanging portion.

[0005] One aspect of the disclosure relates to a method of forming an overhang on a component, the method including forming a surface on the component, the surface being at an angle that is neither perpendicular nor parallel to a target outer planar surface of the overhang. The method includes sequentially depositing a plurality of layers of material on the component, the plurality of layers of material approximating dimensions of the overhang. The method includes machining the plurality of layers of material to form the overhang and the target outer planar surface, the target outer planar surface being at an angle to the plurality of layers of material.

[0006] One aspect of the disclosure provides a turbomachine component comprising a body having a first side, a second side, and a longitudinal axis, and an overhanging portion extending in an overhanging manner from at least one of the first side and the second side of the body, at least a portion of the overhanging portion including a plurality of layers of material, each layer of material extending perpendicular to the longitudinal axis of the body.

[0007] Another aspect of the disclosure provides a turbomachine component comprising a body having a first side and a second side, and an overhanging portion extending in an overhanging manner from at least one of the first side and the second side of the body, at least a portion of the overhanging portion including a first plurality of layers of material extending in a first direction and a second plurality of layers of material extending in a second direction in a non-planar orientation relative to the first direction of the first plurality of layers of material.

[0008] One aspect of the disclosure relates to a method including adding a section to a part, the section including an uphanging portion, and adding includes sequentially depositing a first plurality of layers of material on the part extending in a first direction and sequentially depositing a second plurality of layers of material on the part extending in a second direction different from the first direction. The second plurality of layers of material mates with the first plurality of layers of material, the first plurality of layers of material and the second plurality of layers of material collectively approximating dimensions of the section including the uphanging portion and being non-planar with respect to one another. The method includes machining the first plurality of layers of material and the second plurality of layers of material to form the section including the uphanging portion.

[0009] The illustrative aspects of the present disclosure are designed to solve the problems described herein and / or other problems not discussed. [Brief description of the drawings]

[0010] These and other features of the present disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings which depict various embodiments of the present disclosure. [Figure 1] FIG. 1 is a schematic diagram of an exemplary industrial application in the form of a gas turbine including a turbomachinery component having an overhang, such as a flared tip rail, in accordance with an embodiment of the present disclosure. [Diagram 2] FIG. 2 is a cross-sectional view of a compressor section of the gas turbine of FIG. 1. [Diagram 3] FIG. 2 is a cross-sectional view of a turbine section of the gas turbine of FIG. [Figure 4]1 is a perspective view of an exemplary turbomachinery component in the form of a turbine rotor blade having a flared tip rail; [Diagram 5] 1 is a cross-sectional view of an exemplary overhang in the form of a flared tip rail including the portion to be removed and the intended removal line. FIG. [Figure 6] FIG. 6 is a cross-sectional view of the part after portions of FIG. 5 have been removed to create a surface for building a new overhang portion. [Figure 7] 1 is a cross-sectional view showing the sequential deposition of multiple layers of material onto a surface of a component. [Figure 8] FIG. 2 is an enlarged cross-sectional view showing multiple layers of material each made up of a series of weld beads. [Figure 9] FIG. 2 is a schematic plan view showing a series of weld beads of two layers of material running in different directions. [Figure 10] FIG. 8 is a cross-sectional view showing how the part in FIG. 7 is machined to form a new overhang portion. [Figure 11] 1 is a cross-sectional view of an overhang portion of a flared tip rail shape, including a portion to be removed and a planned removal line. [Figure 12] FIG. 12 is a cross-sectional view of the part after removing the portion of FIG. 11 and rotating the part to create a surface for building a new overhang portion. [Figure 13A] 13 is a cross-sectional view of the sequential deposition of multiple layers of material onto a surface of the component of FIG. 12 in a substantially horizontal position. [Figure 13B] 13B is a cross-sectional view showing how a plurality of material layers are sequentially laminated on a surface at a rotation angle different from that of FIG. 13A. [Figure 14] The portion of Figures 13A-B is shown in cross section to illustrate machining to form the new overhang. [Figure 15] 7 is a cross-sectional view showing the sequential deposition of multiple layers of material in a first direction on a first surface of the component of FIG. 6. [Figure 16] FIG. 7 is a cross-sectional view of the part after removing portions of FIG. 6 and, optionally, creating two surfaces for constructing a new overhang portion. [Figure 17] FIG. 2 is a cross-sectional view of the part after rotating the part and depositing the first plurality of layers of material. [Figure 18A] 4 is a cross-sectional view illustrating sequential deposition of a second plurality of layers of material in a second direction on a second surface of the component. [Figure 18B] 4 is a cross-sectional view illustrating sequential deposition of a second plurality of layers of material in a second direction on a second surface of the component. [Figure 18C] 1 is a cross-sectional view of a part after repeated sequential deposition of first and second multiple layers of material onto the part during rotation of the part. [Figure 18D] 1 is a cross-sectional view showing the sequential lay-up of multiple layers of material at non-perpendicular angles to a part; [Figure 18E] 1 is a cross-sectional view showing the sequential lay-up of multiple layers of material at non-perpendicular angles to a part; [Figure 19] 1 is a cross-sectional view of a first plurality of layers of material being sequentially deposited in a first direction on a first surface of a component to form a stepped extension. [Figure 20] FIG. 20 is a cross-sectional view of the part of FIG. 19 after rotation. [Figure 21] 21 is a cross-sectional view showing the sequential deposition of multiple layers of material in a second direction on a second surface of the component of FIG. 20. [Figure 22] 21 is shown in cross section showing how the portion of FIG. 21 is machined to form the new overhang portion. [Figure 23] 1 is a cross-sectional view of a pair of overhangs in an exemplary section of a dual flared tip rail configuration including the portion to be removed and the intended removal line; FIG. [Figure 24] FIG. 13 is a cross-sectional view illustrating an exemplary overhang in the form of an inwardly extending double flared tip rail. [Diagram 25] 1 is a cross-sectional view of an exemplary overhang in the form of a flared tip rail with a portion removed and rotated a predetermined angle to form an inclined build surface. [Figure 26] 1 is a cross-sectional view showing the sequential deposition of multiple layers of material onto an inclined surface of a component.

[0011] It should be noted that the drawings of the present disclosure are not necessarily to scale. The drawings are intended to depict only typical aspects of the present disclosure and therefore should not be considered as limiting the scope of the present disclosure. In the drawings, like numbering represents like elements between the drawings. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Aspects and advantages of the present application will be set forth below in the following description, or will be obvious from the description, or may be learned through the practice of the present disclosure. Reference will now be made in detail to the present embodiments, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical designations to refer to features in the drawings. It will be understood that each example is provided to illustrate, but not to limit, the disclosure. Indeed, it will be apparent to one skilled in the art that modifications and variations can be made in the present disclosure without departing from the scope or spirit thereof. For example, features illustrated or described as part of one embodiment may be used in another embodiment to yield yet a further embodiment. The present disclosure is intended to cover such modifications and variations as come within the scope of the appended claims and their equivalents. Certain terms have been selected to describe the present disclosure and its constituent subsystems and components. Wherever possible, these terms have been selected based on terms common to the art. It will nevertheless be understood that such terms are often subject to different interpretations. For example, what is referred to herein as a single component may be referred to elsewhere as being made up of multiple components, and what is referred to herein as including multiple components may be referred to elsewhere as being a single component. Accordingly, in understanding the scope of the present disclosure, attention should be paid not only to the specific terminology used, but also to the structure, configuration, function, and / or use of the components referenced and described, including the manner in which the terminology relates to the various figures, and to the precise use of the terms in the appended claims. Additionally, although the following examples are presented in the context of an exemplary application of turbomachinery blades that may be used in the compressor or turbine of a gas turbine system, the technology of the present application is also applicable to other categories of turbomachinery, without limitation, and many other industrial parts, as will be understood by one of ordinary skill in the relevant art.

[0013] Given the nature of the operation of a gas turbine, certain terms are particularly useful in describing certain aspects of its function and may be advantageous in describing the disclosed methods. As will be understood, these terms may be used in describing a gas turbine or one of its subsystems, such as a compressor, combustor, or turbine, as well as in describing or claiming a component or subcomponent for use therewith. In the latter case, the terms should be understood as describing those components as they would be properly installed and / or function within a gas turbine engine or major subsystem. These terms and their definitions, unless otherwise noted, are as follows:

[0014] The terms "forward" and "aft" refer to directions relative to the orientation of the gas turbine, and more specifically, the relative positioning of the compressor and turbine sections of the engine. Thus, as used herein, the term "forward" refers to the compressor end, while "aft" refers to the turbine end. It will be understood that each of these terms may be used to indicate a direction of movement or a relative position along the central axis of the engine. As discussed above, these terms may be used to describe attributes of a gas turbine or one of its major subsystems, as well as components or subcomponents located therein. Thus, for example, when a component such as a turbomachine blade is described or claimed to have a "forward face," it can be understood to refer to a face that faces in a forward direction defined by the orientation of the gas turbine (i.e., the compressor is designated as the forward end and the turbine as the aft end). Taking a major subsystem such as a turbine as another example (and assuming a typical gas turbine arrangement as shown in FIG. 1), the forward and aft directions can be defined relative to the forward end of the turbine, where the working fluid enters the turbine, and the aft end of the turbine, where the working fluid exits the turbine.

[0015] As used herein, the terms "downstream" and "upstream" are used to indicate a location within a given conduit or flow passage relative to the direction of flow (hereinafter "flow direction") moving within the given conduit or flow passage. Thus, the term "downstream" refers to the direction in which fluid flows through a given conduit, and the term "upstream" refers to the opposite direction. These terms may be interpreted to refer to the flow direction through the conduit in normal or expected operation. Given the configuration of gas turbines, particularly the arrangement of the compressor and turbine sections about a common shaft or rotor, as well as the cylindrical configuration common to many combustor types, terms describing location relative to an axis may be used routinely herein. In this regard, it will be understood that the term "radial" refers to movement or location perpendicular to the axis. In this regard, it may be required to describe a relative distance from the central axis. In such cases, for example, if a first component is located closer to the central axis than a second component, the first component may be described as being either "radially inside" or "inboard" of the second component. On the other hand, if the first component is located further away from the central axis, the first component would be described as being either "radially outward" or "outboard" of the second component. As used herein, the term "axial" refers to movement or location parallel to the axis, and the term "circumferential" refers to movement or location around the axis. Unless otherwise noted or clear from the context, these terms should be interpreted relative to the central axis of the compressor and / or turbine sections of the gas turbine, defined by the rotor extending therethrough, even when describing or asserting attributes of non-integral components such as rotor or stator blades that function therein.

[0016] The term "turbomachine blade" or "blade", without further specification, is a reference to a rotating blade of either the compressor or the turbine, and thus may include both compressor rotor blades and turbine rotor blades, and a reference to a stationary blade of either the compressor or the turbine, and thus may include both compressor stator blades and turbine stator blades. The term "blade" may be used generally to refer to either type of blade. Thus, without further specification, the term "turbomachine blade" or "blade" encompasses all types of turbine engine blades, including compressor rotor blades, compressor stator blades, turbine rotor blades, turbine stator blades, etc.

[0017] Furthermore, as explained below, certain descriptive terms may be used regularly herein: the terms "first," "second," and "third" may be used interchangeably to distinguish one component from another, and are not intended to imply a position or importance of the individual components.

[0018] As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It will be further understood that as used herein, the terms "comprise" and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. "Optional" or "optionally" means that the subsequently described event or circumstance may or may not occur, or that the subsequently described component or element may or may not be present, and that the description will include instances in which the event occurs or the element is present and instances in which it does not occur or is not present.

[0019] When an element or layer is referred to as being "on," "engaged," "connected," or "coupled" to another element or layer, it may be directly engaged, connected, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly," "directly engaged," "directly connected," or "directly coupled" to another element or layer, there may not be intervening elements or layers. Other words used to describe relationships between elements should be interpreted similarly (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0020] By way of background, and referring now specifically to the figures, FIGS. 1-3 illustrate an exemplary gas turbine in accordance with the present disclosure or in which turbomachinery components of the present disclosure may be used. FIG. 1 is a schematic representation of a gas turbine 10. In general, gas turbines operate by extracting energy from a pressurized flow of hot gas produced by combustion of a fuel in a flow of compressed air. As illustrated in FIG. 1, the gas turbine 10 may be configured with an axial compressor 12 mechanically coupled to a downstream turbine section or turbine 14 by a common shaft or rotor, and a combustor 16 disposed between the compressor 12 and the turbine 14. As shown in FIG. 1, the gas turbine 10 may be formed about a common central axis 18.

[0021] FIG. 2 shows a diagram of an illustrative multi-staged axial compressor 12 that may be used in the gas turbine 10 of FIG. 1. As shown, the compressor 12 may have multiple stages, with each stage including a row of compressor rotor blades 20 and a row of compressor stator blades 22. Thus, a first stage may include a row of compressor rotor blades 20 that rotate about a central shaft, followed by a row of compressor stator blades 22 that remain stationary during operation. FIG. 3 shows a partial view of an exemplary turbine section or turbine 14 that may be used in the gas turbine 10 of FIG. 1. The turbine 14 may also include multiple stages. Three exemplary stages are shown, but there may be more or fewer. Each stage may include a number of turbine nozzles (i.e., stator blades) 24 that remain stationary during operation, followed by a number of turbine buckets (i.e., rotor blades) 26 that rotate about a shaft during operation. The turbine stator blades 24 are generally circumferentially spaced apart from one another and fixed to the outer casing about the axis of rotation. The turbine rotor blades 26 may be mounted on a turbine wheel or rotor disk (not shown) for rotation about a central axis. It will be understood that the turbine stator blades 24 and the turbine rotor blades 26 are in a hot gas path or working fluid flowpath through the turbine 14. The flow direction of the combustion gases or working fluid in the working fluid flowpath is indicated by the arrows.

[0022] In one example of the operation of the gas turbine 10, the rotation of the compressor rotor blades 20 in the axial compressor 12 may compress a flow of air. In the combustor 16, energy may be released when the compressed air is mixed with fuel and ignited. The resulting flow of hot gas or working fluid from the combustor 16 is then directed onto the turbine rotor blades 26 and induces the rotation of the turbine rotor blades 26 about a shaft. In this manner, the energy of the flow of working fluid is converted into mechanical energy of the rotating blades, which, given the connection between the rotor blades and the shaft, become a rotating shaft. The mechanical energy of the shaft may then be used to drive the rotation of the compressor rotor blades 20 such that a required supply of compressed air is generated, and / or may be used, for example, to generate electricity, a generator.

[0023] For background purposes, Figure 4 illustrates a perspective view of an exemplary component 28 having an overhang 30. For purposes of illustration, the component 28 is illustrated as a flare tip turbomachine blade 25, and more specifically, a turbine rotor blade 26. It should be noted that the teachings of the present disclosure are applicable to any component 28 having an overhang 30 other than a turbomachine blade 25, as described herein, such as other hot gas path (HGP) portions of the gas turbine 10. The teachings of the present disclosure are also applicable to other industrial components having overhangs.

[0024] The turbomachine blade 25 may include a root 31 configured for attachment to a rotor disk. The root 31 may include a dovetail 32 configured for attachment to a corresponding dovetail slot in an outer periphery of the rotor disk, for example. The root 31 may further include a shank 34 extending between the dovetail 32 and a platform 36. The platform 36, as shown, generally forms an interface between the root 31 and an airfoil 40, which is an active component of the turbine bucket 26 that intercepts the flow of working fluid through the turbine 14 to induce the desired rotation. The platform 36 may define an inboard end of the airfoil 40. The platform 36 may also define a portion of an inboard boundary of a flow path of the working fluid through the turbine 14.

[0025] A turbomachine blade airfoil 40 typically includes a concave pressure face 42 and a circumferentially or laterally opposed convex suction face 44. The pressure face 42 and suction face 44 extend axially between opposed leading and trailing edges 46, 48, respectively, and may extend radially between an inboard end, which may be defined at a junction with the platform 36, and an outboard tip, which may include a flared tip rail. The airfoil 40 may include a curved or contoured shape designed to promote desired aerodynamic performance.

[0026] As used herein, the turbomachine blades 25 and their components may be described according to orientation characteristics of the turbine 14. In such cases, it should be understood that the turbomachine blades 25 are assumed to be properly installed within the turbine 14. Such orientation characteristics may include radial, axial, and circumferential directions defined relative to the central axis 18 ( FIG. 1 ) of the turbine 14. The forward and aft directions may be defined relative to a forward end of the turbine 14, where the working fluid enters the turbine 14 from the combustor 16, and an aft end of the turbine 14, where the working fluid exits the turbine 14. The direction of rotation may be defined relative to an expected direction of rotation of the turbomachine blades 25 about the central axis 18 ( FIG. 1 ) of the turbine 14 during operation.

[0027] As indicated above, the present disclosure provides a method of forming or repairing a part 28 having an overhang 30, e.g., a flared tip of a turbomachine blade 25. For repair purposes, the method may include removing a portion and adding a portion to the part. For purposes of initially forming the part 28, the method may add a section to a portion of the part 28 already formed. In either case, the section added or formed includes the overhang. Adding includes sequentially laying down one or more layers of material on the part. When completed, the layers of material approximate the dimensions of the section including the overhang. Sequential deposition can be accomplished by a number of methods to form altered layers in a cross section, including, for example, laser welding, cold metal transfer (CMT), tungsten inert gas (TIG) welding, laser sintering, direct metal laser melting (DMLM), net shape methods, near net shape methods, etc. The method and the resulting parts formed thereby can be formed by net shape methods that minimize or eliminate post-build processing or finishing. The method can include machining at least one of the multiple layers of material to form a section including an overhang.

[0028] 5 is an enlarged cross-sectional view of a component 28 having a body 60 having a first side 62 and an opposing second side 64 according to an embodiment of the present disclosure. The body 60 may also have a longitudinal axis 75. The longitudinal axis may be any reference axis of the body 60, for example, through its length. In terms of the airfoil 40, the longitudinal axis may be a radial axis as the airfoil is disposed in the gas turbine 10 (FIG. 1). The overhanging portion 30 extends in an overhanging manner from the first side 62 of the body 60, for example. The overhanging portion 30 lacks vertical structural support at a portion thereof. In one embodiment, the overhanging portion 30 faces an opposing member 66 on the second side 64 of the body 60 and has more mass than the opposing member 66. In the illustrated example, the component 28 includes a turbomachine blade 25 that includes, for example, a flare tip rail 70 that overhangs the blade's suction face 44 at the first side 62. The flare tip rail 70 is thus an example of an overhang portion 30 ( FIG. 4 ) of the component 28. The body 60 includes an airfoil 40, with the flare tip rail 70 facing an opposing member 66 in the form of a radially extending tip rail 134 that extends from an end of the airfoil 40. The flare tip rail 70 extends circumferentially relative to the axis 18 ( FIG. 1 ) of the gas turbine 10. In other embodiments, the overhang portion 30 may be facing another overhang portion, for example, the flare tip rail 70, which may or may not have a different mass, and may extend around the periphery of the airfoil 40 (see, for example, FIGS. 23 and 24 ).

[0029] The damaged overhanging portion may include an overhanging flare tip rail 70, i.e., an overhanging flare tip rail lacking structural support. Portion 72 may include any structure desired to be removed and may include an undamaged portion or a portion having various damages, including but not limited to worn surfaces, cracks, openings, roughness, and the like. In this situation, as shown in FIG. 6, portion 72 may be removed from part 28 to form surface 74 on the part, for example, on turbomachine blade 25. Portion 72 may also be defined by surface / line 74a, where the removed portion is deeper and extends to the non-flared section of suction face 44. Portion 72 may be removed using any technique now known or later developed, including but not limited to electrical discharge machining (EDM), mechanical cutting / grinding, laser cutting, and the like. As shown in FIG. 6, some remnants of flared tip rail 70 may or may not remain, but portion 72 is removed to form surface 74 that may reshape the removed portion. Surface 74 may be flat, curved, or have a three-dimensional shape or profile. As also shown in FIG. 6, in one embodiment, the angle of surface 74 may be in a substantially horizontal plane, i.e., with the body in a vertical position-longitudinal axis 75 vertical. As described herein, surface 74 may also be formed at a non-horizontal angle, with the part rotated as necessary to allow for the formation of new layers. In one non-limiting example, at most half of flared tip rail 70 is removed, e.g., based on at most half of portion 72 being removed. In another non-limiting example, at least half of flared tip rail 70 is removed, e.g., based on at least half of portion 72 being removed.

[0030] Embodiments of the present disclosure may also include initial manufacture of the flared tip rail 70. In this case, a starting structure such as that shown in FIG. 6 may be manufactured using any suitable technique for the material and structure being constructed. Non-limiting examples may include casting and additive manufacturing. In either case, a surface 74 is generated upon which the overhang portion is to be constructed.

[0031] FIG. 7 is a cross-sectional view of adding a section 76 to part 28, where section 76 includes a new overhang portion 78. The addition involves sequentially depositing a plurality 80 of material layers 82 onto part 28, i.e., onto surface 74. Collectively, when completed, the plurality of material layers 82 approximate the dimensions of the section including the new overhang portion 78. That is, the added section approximates the dimensions of the desired new overhang portion 78 being added, or the portion 72 being replaced. As used herein, "approximate dimensions" generally indicates that the new overhang portion 78 may be formed by machining material removal, with little or no additional material addition. The addition of material layers 82 may be provided in a number of ways. For example, material layers 82 may be formed using laser welding, laser cladding, cold metal transfer (CMT), tungsten inert gas (TIG) welding, additive manufacturing, metal sintering, direct metal laser melting (DMLM), etc. In this case, as shown in the enlarged cross-sectional view of material layers 82 in FIG. 8 , sequentially depositing multiple 80 material layers 82 onto part 28 includes forming a series of weld beads 84 to form each layer 82. Any number of weld beads 84 may be used to form a layer. The layers can be formed using any pattern of welds, such as a continuous spiral weld bead starting at the center or periphery, or side-by-side individual linear weld beads extending from side to side of surface 74, or a combination thereof.Surface 74 can be positioned in a substantially horizontal position (e.g., within ±3° of horizontal) during sequential deposition to promote even deposition of material, and portion 72 can then be replaced by sequentially depositing at least one of multiple layers of material 80 onto surface 74.

[0032] In FIG. 7, only a single plurality 80 of layers of material 82 are used. Here, the second end 90 of the layers of material 82 is arranged in a stepped manner to approximate the dimensions of the overhang (to be formed). In one example, the first end 86 of the single plurality of layers of material 82 is shown generally aligned with the surface 88 of the part 28, and the second end 90 of the single layer of material 82 is stepped to approximately the same dimensions as the overhang (to be formed). Here, the second end 90 progressively extends to a greater extent beyond the suction face 44 of the turbomachine blade 25 in an overhanging manner as it moves upward as shown. Here, each layer 82 may have its first end 86 aligned radially or vertically. Note that the first end 86 of the single plurality of layers of material 82 may not be aligned exactly as shown and may have uneven edges relative to the surface 88 of the part 28. These uneven edges can later be machined to align with surface 88 of component 28 .

[0033] FIG. 9 is a schematic plan view of weld beads 84 of layers 82. As shown, weld beads 84 of different layers 82A may be angled relative to weld beads 84 of other layers 82B. For example, a series of weld beads 84 of at least one first material layer 82A of the plurality 80 of material layers 82 may be formed at a non-parallel angle relative to a series of weld beads 84 of at least one second material layer 82B of the same plurality 80 of layers. Any angle may be employed to foster strength in the new section 76 (FIG. 10). In addition to the orientation of the weld beads, the sequential layering may be performed in a manner that controls the local temperature of the structure to prevent thermal cracking. For example, a user may hop from location to location on the build surface 74 to allow cooling in one area while working in another area, ensuring that the new weld bead is applied in the cooled location before applying the new weld bead.

[0034] FIG. 10 illustrates portion 28 after machining a plurality 80 of layers of material 82 to form a new section 76 including a new overhang portion 78. If the process replaces portion 72 (FIG. 5), overhang portion 78 may match the shape and dimensions of portion 72 (FIG. 5). Alternatively, it may have a different shape and dimensions to provide improved performance and / or life. Machining may include any manner of material removal that allows for a blending of surfaces resulting in the desired shape and dimensions for new section 76. Non-limiting and non-exhaustive examples of machining may include milling, grinding, cutting, polishing, etc. As previously discussed, body 60 may include airfoil 40 of turbomachine blade 25. In this case, overhang portion 78 includes a flared tip rail 70 extending from one of first side 62 (not shown) and second side 64 of airfoil 40. In FIG. 10, the turbomachine blade 25 includes a flared tip rail 70 extending from the airfoil 40 with a radially-facing outer surface 138 of the overhanging portion 78 parallel to the axis 18 of the turbomachine.

[0035] In FIG. 7 , the surface 74 is formed to be parallel to the radially facing outer surface 92 of the new section 76, perhaps extending parallel to the axis 18 ( FIG. 1 ) of the gas turbine 10 ( FIG. 1 ). In other words, the surface 74 extends perpendicular to the longitudinal axis 75 of the part, or in terms of the turbomachine blade, the radial axis 75 of the body 60 of the airfoil 40. As a result, the part 28 includes at least a portion of an overhang 78 that includes a plurality 80 of layers of material 82, each layer of material 82 extending at an angle perpendicular to the longitudinal axis 75 of the body 60. The portion of the overhang 78 may include at most half of the overhang 78 that extends from the floor 136 to the radially facing outer surface of the overhang 78 (when the blade is installed), or more than half of the overhang 78. In an alternative embodiment, the part 28 may be rotated so that the surface 74 is inclined from the horizontal, as shown in FIG. 25 . For example, the rotation angle θ1 may be about 15° to about 60° such that the longitudinal axis 75 of the part 28 is rotated at the rotation angle θ1 from vertical. FIG. 26 is a cross-sectional view of adding a new section 76 to the part 28, the new section 76 including a new overhang portion 78. The addition involves sequentially depositing a plurality 80 of graded material layers 82 onto the part 28, i.e., onto the sloped surface 74. Collectively, when completed, the plurality 80 of material layers 82 approximate the dimensions of the new section 76 including the overhang portion 78 at a larger overhang angle than would be obtained with a flat surface build, as shown in FIG. 7. That is, the added section 76 approximates the dimensions of the desired new overhang portion 78 being added, or the damaged portion 72 being replaced (FIG. 5), or the larger overhang angle, as desired. For example, the overhang angle θ2 may be about 50° to about 65°, or about 55° to about 60°. The overhang angle θ2 is measured between the longitudinal axis 75 of the part and a line intersecting the bottom corner (or edge) of the overhang material layer 82, as shown in Figure 26. The beveled construction reduces the perceived overhang of each layer, allowing greater amounts of overhang to be successfully achieved.

[0036] As shown in FIG. 11 , in an alternative embodiment, removing portion 72 of component 28 may include creating a surface 94 that is not perpendicular to longitudinal axis 75 of body 60, i.e., radial axis 75 of body 60 of airfoil 40. Rather, surface 94 may be at an acute angle δ relative to longitudinal axis 75 of body 60, i.e., radial axis 75 of airfoil 40. For clarity, the acute angle is between 0° and 90°. Surface 94 may also be at an acute angle α relative to axis 18 of gas turbine 10 (added in phantom in FIG. 11 ). Additionally, surface 94 will be at an angle that is neither perpendicular nor parallel to a target radially facing outer flat surface 96 ( FIG. 14 ) of new overhang portion 78 of the final product, i.e., new flare tip rail.

[0037] As shown in FIG. 13A, the surface 94 can be rotated to be substantially horizontal (±3°) before sequentially depositing the plurality 80 of material layers 82 thereon. Alternatively, as shown in FIG. 13B, the part 28 can be rotated to position the surface 94 at an angle β other than horizontal and vertical before sequentially depositing the plurality 80 of material layers 82. The part 28 can alternatively be rotated to the position of FIG. 13B after a number of material layers 82 have been sequentially deposited. The angle β can be any angle that allows for a desired stepping of the plurality 80 of material layers 82, i.e., that is not substantially horizontal as defined herein. For example, the angle β can be such that the end 98 of the layer 82 steps outward in such a way that the end can later be machined to align with the surface 88, and the end 100 of the layer 82 steps outward in such a way that it forms a new overhang portion 78 of the part 28. The angle β can allow for the formation of an overhang portion 78 having an extent that could not be formed if the surface 94 were horizontal. For example, the outward length L2 (FIG. 14) of the new overhang portion 78 may be greater than the initial outward length L1 (FIG. 11) of the original overhang portion 30, and the angle ε2 of the new overhang portion 78 relative to the radial axis 75 of the body 60 may be greater than the initial angle ε1 (FIG. 11) of the original overhang portion 30 relative to the radial axis 75 of the body 60. The angle β may be any angle that allows for sequential stacking without allowing for undesirable formation of layers, for example in the form of dripping, slumping or breaking.

[0038] 13A-B also illustrate sequential laying up of the plurality 80 of layers of material 82 on the surface 94. In this case, each end 98, 100 of the layers 82 may be stepped. That is, as shown in FIG. 13A-B, sequential laying up of the plurality of layers of material 82 may include forming a first end 98 of the plurality of layers of material 82 in a stepped manner from a first side of the surface 94 and forming a second end 100 of the plurality of layers of material 82 in a stepped manner from a second side of the surface 94. One of the first end and the second end (100 as shown) approximates the dimensions of the section 76 including the overhang portion 78, as described herein. The end 98 may be stepped to align with the surface 88 of the part 28 when completed, and the end 100 may be stepped to form a new overhang portion 78 of the part 28, e.g., a new flared tip rail of a turbomachine blade 25, as described above. Here, as shown in phantom lines in Figure 14, after machining, the layer 82 of the new overhang portion 78 of the finished product extends at an acute angle α with respect to the axis 18 (shown diagrammatically in phantom lines) of the gas turbine 10 (Figure 1), at an acute angle α with respect to a target surface 96 (Figure 14), and at an acute angle δ with respect to the longitudinal axis 75 of the body 60 or part 28 (i.e., the radial axis 75 of the airfoil 40). Furthermore, the target surface 96, when completed, is at an angle α with respect to the plurality 80 of layers of material 82 and the surface 94 upon which the layers will be built. It should be understood that although the target surface 96 is shown as a plane, it may not be planar; for example, the surface 96 may be curved or have a three-dimensional profile.

[0039] FIG. 14 illustrates machining the plurality 80 of layers 82 of material to form an overhang 78 and a target outer flat surface 138. The target outer (flat) surface 96 is at an angle α to the plurality 80 layers 82 of material. The turbomachinery component 28 illustrated in FIG. 14 includes a body 60 having a first side 62, a second side 64 that may oppose the first side 62, and a longitudinal axis 75. The overhang 76 overhangs from at least one of the first side 62 (not shown) and the second side 64 of the body 60. FIG. 23 illustrates an overhang extending from both sides. As discussed in FIG. 14, at least a portion of the overhang 78 includes the plurality 80 layers 82 of material, each layer 82 extending at an acute angle δ to the longitudinal axis 75 of the body 60. In one embodiment, a radially extending tip rail 134 may extend from the airfoil 40 (from the other side of the body 60), and a radially facing outer surface 138 of the overhang portion 78 may be parallel to the axis 18 of the turbomachine when in the operating position.

[0040] 15-22, in another embodiment of the present disclosure, one or more layers of material 82 may be used to form a new section 76 including a new overhang portion 78. Here, the section 76 may be added to the part 28 including the overhang portion 78 by sequentially laminating one or more layers of material. The method may include sequentially laminating a first layer of material to a part extending in a first direction and sequentially laminating a second layer of material to a part extending in a second direction different from the first direction, e.g., two layers of material built on perpendicular faces formed in the part. The second layer of material generally meets with the first layer of material, i.e., forms the new section 76. Different layers of each layer of material may differ in material, e.g., the layers of material may alternate materials within a given layer of material. Additionally or alternatively, the material within each layer of material may be the same, but the two layers of material may use different materials. Either or both of the layers of material 82 may use the same material or different materials as the body 60.

[0041] As shown in Figures 6 and 15, when applied to a used part, any portion 72 of the part 28 may be removed to form the surface 74. Otherwise, the formation of the new section 76 may be from an initially formed part, as shown in Figure 6. In one embodiment, as shown in Figure 15, adding the section 76 to the part 28 including the overhang portion 78 may include sequentially depositing a first plurality 110 of material layers 82 onto the part 28 that extends in a first direction, e.g., generally horizontal as shown, but possibly at some angle away from the horizontal. In this example, the first plurality 110 of layers 82 may be sequentially formed horizontally on the part 28 in a manner that consumes a portion 112 (Figure 6) of the flared tip rail 70. Alternatively, as shown in Figure 16, any desired material, such as the portion 112 (Figure 6) of the flared tip rail 70, may be removed to form another surface 114 prior to the first sequential deposition. That is, another portion 112 of the part 28 is removed to form the another surface 114. In this case, after any necessary rotations, the layers 82 may be formed horizontally on the part 28 on the surface 114 in sequence, i.e., without consuming other material. In this setup, the sequential stacking of the first plurality 110 of material layers 82 rests on the surface 114 and forms an extension 116 of the surface 114. The ends 118 of the layers 82 are ideally aligned with the surface 74 as formed, but if not, can be machined to align with the surface 74. In FIG. 15, the sequential stacking of the first plurality 110 of material layers 82 forms an extension 116 of the surface 74. As described herein, alternative embodiments may form extensions with stepped ends (see, e.g., FIGS. 18C and 19).

[0042] 17 illustrates rotating the part 28 so that the surface 74 is at a different angle, e.g., substantially horizontal, and FIG. 18A illustrates sequentially layering the second plurality 120 of material layers 82 on the part 28 extending in a second, different direction, e.g., perpendicular to the first plurality 110 of material layers 82. In this embodiment, as previously described, the sequential layering of the first plurality 110 of material layers 82 creates the extension 116 of the surface 74, and as shown in FIG. 18A, the sequential layering of the second plurality 120 of material layers 82 is on the first surface 74 and the extension 116 of the first surface 74. The second plurality 120 of material layers 82 meet the first plurality 110 of material layers 82, i.e., generally they come together and mate or generally mate together.

[0043] 18A-18E show various embodiments in which the first plurality 110 of material layers 82 and the second plurality 120 of material layers 82 collectively approximate the dimensions of the new section 76 including the new overhang portion 78 and are non-planar with respect to one another. As will be described, the second plurality 120 of material layers 82 can extend in various non-planar directions (i.e., not in the same plane) relative to the first direction of the first plurality 110 of material layers 82. FIGS. 17 and 18A show an embodiment in which the ultimately horizontal second plurality 120 of material layers 82 extends above the vertical first plurality 110 of material layers 82, i.e., the angle γ between the surfaces 74, 114 is substantially perpendicular (90°±2°). FIG. 18B shows an alternative embodiment in which the plurality of material layers 110, 120 are positionally reversed. That is, second plurality 120 of layers of material 82 are first formed on surface 74 to provide extension 116. Part 28 is then rotated such that surface 114 and extension 116 are buildable to form first plurality 110 of layers of material 82. First plurality 110 of layers of material 182 terminates by extending adjacent ends of second plurality 120 of layers of material 82 forming extension 116.

[0044] 18C shows another alternative embodiment of the part after repeated sequential lamination of each plurality. In other words, fewer than all of the material layers 82 of the first and second plurality 110, 120 are formed on the part during rotation of the part. Here, a number of layers, e.g., 1-4, less than all of the layers of the first or second plurality 110, 120 of material layers 82 are built on one surface 74, 114, and then the part is rotated and another number of layers, e.g., 1-4, less than all of the layers of the other plurality 110, 120 of material layers 82 are built on the opposing surface 74, 114. This approach creates a stepped or near stepped interlocking of the groups of layers 82 within each plurality 110, 120. This process can be advantageous for reducing thermal stresses and addressing other mechanical issues.

[0045] Figures 18D-E show other alternative embodiments of parts in which surfaces 74, 114 are formed in non-planar orientations and have a non-perpendicular angle γ, where the location of surface 74 or 114 in the stack of each of the plurality 110, 120 of material layers 82 can be any location necessary to ensure desired bonding of the layers and accommodate hardware welding constraints. Figure 18D shows surfaces 74, 114 at an obtuse angle γ (90°<γ<180°) and Figure 18E shows surfaces 74, 114 at an angle γ greater than 180°.

[0046] 19-21 show alternative embodiments that are substantially similar to those described in connection with FIGS. 15-18E, except that sequential lamination of first and second pluralities 110, 120 of material layers 82, respectively, creates stair-stepped ends that generally meet with one another. As with FIGS. 15 and 16, the first sequential lamination can consume a portion 112 of the part, or can create another surface 114 by removing a portion 112 of the part and completing lamination on the surface. In either case, prior to lamination, any portion 72 of the part 28 can be removed to create the surface 74, 114 for used part applications.

[0047] FIG. 19 illustrates the sequential lamination of the first plurality 110 of material layers 82 to create a stair-stepped extension 122 of surface 114. FIG. 20 illustrates any necessary rotation of the part, and FIG. 21 illustrates the sequential lamination of the second plurality 120 of material layers 82 onto surface 74 and the stair-stepped extension 122 of surface 74 (FIG. 20). More specifically, the sequential lamination of the second plurality 120 of material layers 82 onto surface 74 is performed to generally interlock the material layer 82 with the stair-stepped extension 122 of surface 74 formed by the first plurality 110 of material layers 82 to form an interlocking bond. Here, as shown in FIG. 21, the two plurality 110, 120 of material layers 82 can have mating stepped ends or generally interlocking stepped ends, possibly with some voids 83 between them in some locations. That is, the ends of the first plurality 110 of material layers 82 meet the ends of the second plurality 120 of material layers 82 in a stepped manner, possibly with some voids 83 therein. Although the surfaces 74, 114 are shown as being perpendicular to one another in Figures 19-22, any of the angles γ described in connection with Figures 18A-E may be employed with the stepped layers.

[0048] FIGURE 22 illustrates part 28 after machining plurality 110, 120 of layers of material 82 to form section 76 including new overhang portion 78. This process may follow any of the described processes for sequentially stacking multiple layers of material. This machining process may be as described in connection with FIGURE 10. While machining is shown performed from the embodiment of FIGURE 21, it will be appreciated that similar machining may be performed for the embodiment of FIGS. 18A-E.

[0049] 22 illustrates a turbomachinery component 28 including a body 60 having a first side 62 and a second side 64. An overhanging portion 78 extends in an overhanging manner from at least one of the first side 62 and the second side 64 (not shown) of the body 60. At least a portion of the overhanging portion 78 extends between a first plurality 110 of material layers 82 extending in a first direction and a second plurality 120 of material layers 82 extending in a second direction in a non-planar direction (see angle γ) relative to the first direction of the first plurality 110 of material layers 82 (see FIGS. 18A-E).

[0050] 23 is an enlarged cross-sectional view of a part 28 having a body 60 with a first side 62 and an opposing second side 64 according to another embodiment of the present disclosure. Here, an overhanging portion 30, 230 extends overhangingly from the first side 62 of the body 60 and from the second side 64 of the body, respectively. Both overhanging portions 30, 230 lack vertical structural support at their portions. In this embodiment, the overhanging portions 30, 230 may have the same mass and extend to the same extent, or one or the other may have more mass and extend to different extents. In the illustrated example, the part 28 includes a turbomachine blade 25 including a flared tip rail 70, 270 that overhangs, for example, the suction face 44 and the pressure face 42 of the blade. It should be noted, however, that the flared tip rail 70 may extend around the entire periphery of the tip of the airfoil 40. Thus, the flare tip rail 70 is one example of an overhang portion 30, 230 of the component 28. The body 60 includes the airfoil 40 and the flare tip rail 70. The flare tip rail 70 extends circumferentially about the axis 18 (FIG. 1) of the gas turbine 10. While FIGS. 5-22 illustrate a process for repairing the flare tip rail 70 on one side of the airfoil 40, it will be readily appreciated that the teachings of the present disclosure may be repeated as many times and with as many build surfaces 74, 94, 114, 116 as necessary. Any number of portions 72 (damaged overhang portions) may be repaired or added.

[0051] FIG. 24 is an enlarged cross-sectional view of a component 28 having a body 60 having a first side 62 and an opposing second side 64, according to another embodiment of the present disclosure. In FIGS. 5-23, the overhang portion(s) 30, 230 extend outwardly relative to the body 60 of the airfoil 40. In FIG. 24, the overhang portions 330, 430 overhang inwardly from the first side 62 of the body 60 and from the second side 64 of the body, respectively. Both overhang portions 330, 430 lack vertical structural support at a portion thereof. In this embodiment, the overhang portions 330, 430 may have the same mass and extend inwardly to the same extent, or one or the other portion may have more mass and extend to different extents. Although not shown, it will be appreciated that one of the inwardly extending overhang portions 330, 430 may be replaced with a radially extending tip rail 134 as in FIG. 5. The overhangs 330, 430 may be repaired or added according to any of the embodiments described herein. It should be understood that the overhangs may extend over the pressure surface 42, the suction surface 44, and the floor surface 136, or all of these surfaces / surfaces, or a combination thereof.

[0052] The component 28 may include a metal. In one embodiment, the component 28 is made from a metal, such as a superalloy or metal alloy having a columnar grain structure (e.g., a directionally solidified (DS) blade). In one embodiment, the component 28 can be made from a first metal, which can include a pure metal or an alloy. As used herein, "superalloy" refers to an alloy that has a number of superior physical properties compared to conventional alloys, including but not limited to high mechanical strength, high thermal creep deformation resistance, such as Rene N5, Rene N500, Rene 108, CM247, Haynes alloy, Inconel, MP98T, TMS alloy, CMSX single crystal alloy. In one embodiment, superalloys in which the teachings of the present disclosure may be particularly advantageous are superalloys with high Gamma prime (γ') values. "Gamma prime" (γ') is the primary strengthening phase in nickel-based alloys. Examples of high gamma prime superalloys include, but are not limited to: Rene 108, N4, N5, N500, GTD 444, MarM 247, and IN 738. The new section 76 and the plurality 80, 110, 120 of the material layer 82 may include a first metal, and the turbomachine blade 25 may all be made of the same material. In an alternative embodiment, the section 76 may include a second metal that is different from the first metal. In one embodiment, all of the layers 82 of a particular plurality 80, 110, 120 may be the same material, but a different material than the remainder of the part 28. That is, the part 28 includes a first metal, and the plurality 80, 110, 120 of the material layer 82 includes a second metal that is different from the first metal. Thus, the new section 76 may be a homogenous material. Alternatively, the different layers 82 of the plurality 80, 110, 120 of material layers 82 may be different, such that the new section 76 has different materials therein. That is, the plurality 80, 110, 120 of material layers 82 can include at least one first material layer including a first metal and at least one second material layer including a second metal different from the first metal.For example, material layer 82 of new section 76, e.g., near surface 74 or surface 114, may match the material of part 28, and layers away from surface 74 or surface 94 may be a different material, e.g., a harder material to better withstand wear. Alternatively, the different layers may have different materials therein. That is, at least one of the plurality 80, 110, 120 of material layers 82 may include at least one first material layer including a first metal, and at least one second material layer may include a second metal different from the first metal. Figures 10, 14 and 22 show the material layers in phantom lines.

[0053] 4, 10, 14, and 22, embodiments of the present disclosure also include a turbomachine component 130 for a gas turbine 10 (FIG. 1). The turbomachine component 130 may include a turbomachine blade 25 including a body 60 in the form of an airfoil 40 having a first side 62 in the form of a suction face 44 and a second side 64 in the form of a pressure face 42, as shown in FIGS. 4 and 5. The turbomachine component 130 in the form of a turbomachine blade 25 may also include a root 31 (FIG. 4). As shown in FIGS. 10, 14, and 22, the turbomachine component 130 may also include a novel overhang portion 78 in the form of a flare tip rail 132 that overhangs from at least one of the first side 62 and second side 64 of the body 60, i.e., from at least one of the pressure face 42 and suction face 44 (described below) of the airfoil 40. As shown in FIG. 14, an overhang portion 78 in the form of a new flared tip rail 132 may oppose a counter member 66 on the second side 64 of the body 60 in the form of a radially extending tip rail 134. The overhang portion 78 and the counter member 66 extend from a floor 136 of the body, e.g., a radially outer surface of the airfoil 40. The overhang portion 30 may have more mass than the counter member 66. As shown in FIG. 23, an overhang portion 30, 230 in the form of a new flared tip rail 232 may be formed on the body 60. It is emphasized that each overhang portion 30, 230 of FIG. 23 may take the form of any of the embodiments described herein. As shown in FIG. 24, an overhang portion 330, 430 in the form of a new inwardly extending flared tip rail(s) may also be formed on the body 60. In either case, the overhangs extend from the floor 136, i.e., the radially outer surface of the airfoil 40. The overhangs 30, 230, 330, 430 may have the same or different masses and may extend to the same or different extents. In either case, the overhangs 30, 230, 330, 430 extend circumferentially relative to the axis 18 (FIG. 1) of the turbomachine. It should also be noted that the overhangs 30, 230, 330, 430 may take the form of a single unitary overhang that extends about the entire periphery of the airfoil 40.

[0054] As described herein, the overhang portion 30, 230, 330, 430 in the form of the flared tip rail 132 includes at least one of the plurality of layers of material 82 therein. In one embodiment, the plurality of layers 82 are disposed on at most half of the overhang portion extending from the floor surface 136 to the radially facing outer surface 201, i.e., on at most half of the portion 72 to be removed. As shown in FIG. 14 , in one embodiment, it is contemplated that each layer of material 82 extends at an acute angle δ with respect to the radial axis 75 of the body 60 and an acute angle α with respect to the radially facing outer surface 138 of the overhang portion 30, i.e., the radially facing outer surface of the flared tip rail 132. In this configuration, the surface 94 on which the material layers 82 of the plurality 80 of the novel flare tip rail 132 are formed may also extend at an acute angle α relative to the axis 18 ( FIG. 1 ) and radial axis 75 of the body 60 of the gas turbine 10 having the turbomachine blades 26 at an operating location within the turbomachine. In another embodiment shown in FIG. 22 , the flare tip rail 132 may include a first plurality 110 of its material layers 82 extending in a first direction and a second plurality 120 of material layers 82 extending in a second direction in a non-planar direction (not 180°) relative to the first direction of the first plurality 110 of material layers 82. The two plurality of layers may be abutting ( FIGS. 18A-B ), may have mating stepped ends ( FIG. 22 ), or may have generally mating stepped ends with perhaps some voids 83 therebetween at some locations ( FIG. 21 ). In one embodiment, one of the two plurality 120 of material layers 82 can be substantially parallel to the axis 18 ( FIG. 1 ) of the gas turbine 10 ( FIG. 1 ) with the turbomachine component 130 in its operating position within the turbomachine (perpendicular to the radial axis 75). Additionally, the other of the two plurality 110 of material layers 82 can extend in a non-planar direction relative to the plurality 120 of material layers 82. As shown in FIGS. 18A-C, the non-planar direction may be substantially perpendicular, i.e., 90°+ / -2°. FIGS. 18D-E show other non-planar directions that are not substantially perpendicular, i.e., not 90°+ / -2°.

[0055] The body 60 in the form of the airfoil 40 may include a first metal and at least one of the plurality of material layers 82 may include a second metal different from the first metal. In other embodiments, the plurality 80, 110, 120 of material layers 82 may include at least one first material layer therein that includes a first metal and at least one second material layer therein that includes a second metal different from the first metal. That is, within a given plurality of material layers, different materials may be used. For example, the layer 82 of the new section 76 close to the surface 74 may match the material of the part 28, and the layer away from the surface 74 may be a different material, e.g., a harder material to withstand more wear.

[0056] As shown in Figure 8, each material layer 82 may include a series of weld beads 84. As shown in Figure 9, the series of weld beads 84 for at least one first material layer 82A of the plurality of material layers may be at a non-parallel angle to the series of weld beads 84 for at least one second material layer 82B of the plurality of material layers.

[0057] Embodiments of the present disclosure provide several methods for creating layers of material for material addition and / or repair of overhanging portions, such as the flare tip rails of turbine rotor blades, that can be machined to have desired dimensions, shapes, etc. after operation to maintain engine performance.

[0058] The foregoing figures illustrate some of the processes involved in accordance with some embodiments of the present disclosure. In this regard, each figure represents a process associated with an embodiment of the method described. It should also be noted that in some alternative implementations, the acts depicted in the figures may occur out of the order depicted in the figures, or may actually be performed substantially simultaneously or in reverse order, depending on, for example, the acts involved. Also, one skilled in the art will recognize that additional steps describing the processes may be added.

[0059] Approximate words used throughout the specification and claims can be applied to modify any quantitative expression that may be tolerated without resulting in a change in the basic function to which it relates. Thus, values ​​modified by terms such as "about", "approximately", "substantially" and the like should not be limited to the exact values ​​specified. In at least some instances, the approximating language can correspond to the precision of the instrument for measuring the value. In the specification and claims, range limitations can be combined and / or interchanged, and such ranges are specified and include all subranges contained therein, unless the context or language indicates otherwise. "About" applied to a particular value in a range applies to both endpoints and may indicate + / - 10% of the stated value(s), unless dependent on the precision of the instrument for measuring the value.

[0060] Corresponding structures, materials, acts, and equivalents of all means or step-plus-function elements in the following claims are intended to include any structure, material, or act for performing a function in combination with other claim elements as specifically claimed. The description of the present disclosure has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the disclosure in the form disclosed. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. The embodiments have been chosen and described in order to best explain the principles and practical applications of the present disclosure, and to enable others skilled in the art to understand the present disclosure in various embodiments with various modifications as suited to the particular use contemplated. [Explanation of symbols]

[0061] 10:Gas turbine 12:Compressor 14:Turbine 16:Combustor 18:Central shaft 20:Compressor rotor blade 22:Compressor stator blade 24:Turbine nozzle 25:Flare tip turbomachine blade 26:Turbine bucket 28:Component 30:Overhang 31:Root 32:Dovetail 34:Shank 36:Platform 40:Airfoil 42:Pressure face 44:Suction face 46:Leading edge 48:Trailing edge 60:Body 62:First side 64:Second side 66:Counterpart 70:Flare tip rail 72:Part 74:Surface 75:Longitudinal axis 76:Section 78:New overhang 80:Multiple layers of material 82:Material layer 83:Vacuum 92:Radially facing outer surface 94:Surface not perpendicular to radial axis 96: Target radially facing outer flat surface 98: First end 100: Second end 110: First plurality of layers of material 114: Surface 116: Extension 120: Second plurality of layers of material 122: Stepped extension 130: Turbomachinery component 132: Flared tip rail 134: Tip rail 136: Floor 138: Radially facing outer surface 230: Overhang

Claims

1. a body having a first side, a second side and a longitudinal axis; an overhang portion extending in an overhanging shape from at least one of the first side surface and the second side surface of the main body; Equipped with The turbomachine component, wherein at least a portion of the overhang includes a plurality of layers of material, each layer of material extending at an angle perpendicular to a longitudinal axis of the body.

2. The turbomachinery component of claim 1 , wherein the body comprises a first metal and the plurality of layers of material comprises a second metal different from the first metal.

3. 3. The turbomachinery component of claim 1 or 2, wherein the plurality of material layers includes at least one first material layer comprising a first metal and at least one second material layer comprising a second metal different from the first metal.

4. The turbomachine component of claim 1 , wherein each layer of the plurality of layers of material includes a series of weld beads.

5. The turbomachine component of claim 4 , wherein a series of weld beads for at least one first layer of the plurality of layers of materials is at a non-parallel angle relative to a series of weld beads for at least one second layer of the plurality of layers of materials.

6. 4. The turbomachinery component of claim 1, wherein the overhang portion extends from a floor of the body, and the plurality of layers of material are disposed on a maximum half of the overhang portion extending from the floor to an outer surface of the overhang portion.

7. 2. The turbomachine component of claim 1, wherein the body comprises an airfoil of a turbomachine blade, the overhang portion comprises a flared tip rail extending from one of the first and second sides of the airfoil and further comprises a radially extending tip rail extending from the airfoil, and a radially facing outer surface of the overhang portion is parallel to an axis of the turbomachine.

8. A gas turbine comprising the turbomachine component of claim 1.

9. a body having a first side and a second side; an overhang portion extending in an overhanging manner from at least one of the first side surface and the second side surface of the main body; 1. The turbomachine component, wherein at least a portion of the overhang portion includes a first plurality of layers of material extending in a first direction and a second plurality of layers of material extending in a second direction non-planar with respect to the first direction of the first plurality of layers of material.

10. The turbomachinery component of claim 9 , wherein the body comprises a first metal and at least one of the first and second plurality of layers of material comprises a second metal different from the first metal.

11. 11. The turbomachinery component of claim 9 or 10, wherein within each of the first and second pluralities of material layers, at least one first material layer comprises a first metal and at least one second material layer comprises a second metal different from the first metal.

12. The turbomachine component of claim 9 , wherein each layer of material of the first and second pluralities of layers of material includes a series of weld beads.

13. 13. The turbomachine component of claim 12, wherein a series of weld beads for at least one first layer of material of one of the first and second pluralities of layers of material are at a non-parallel angle to a series of weld beads for at least one second layer of material of one of the first and second pluralities of layers of material.

14. 10. The turbomachine component of claim 9, wherein the body comprises an airfoil of a turbomachine blade, the overhang portion comprising a flared tip rail extending from an end of the airfoil, and further comprising a radially extending tip rail extending from the end of the airfoil.

15. The turbomachinery component of claim 9 , wherein ends of the first plurality of layers of material meet ends of the second plurality of layers of material in a stepped manner.

16. adding a section to the part, the section including an overhang; sequentially depositing a first plurality of layers of material onto a component extending in a first direction; sequentially depositing a second plurality of layers of material onto the part extending in a second direction different from the first direction, the second plurality of layers of material meeting the first plurality of layers of material, the first plurality of layers of material and the second plurality of layers of material collectively approximating a dimension of a section including an overhang portion and being non-planar with respect to one another; processing the first and second layers of material to form a section including an overhang; A method comprising:

17. 20. The method of claim 16, wherein the component comprises a first metal and at least one of the first and second plurality of material layers comprises a second metal different from the first metal.

18. 18. The method of claim 16 or 17, wherein at least one of the first plurality of material layers and the second plurality of material layers comprises at least one first material layer comprising a first metal and at least one second material layer comprising a second metal different from the first metal.

19. 19. The method of claim 16, wherein the step of sequentially depositing a first plurality of layers of material and a second plurality of layers of material on the component includes forming a series of weld beads to form each layer.

20. 20. The method of claim 19, wherein a series of weld beads for at least one first layer of the first and second plurality of layers of material are at a non-parallel angle relative to a series of weld beads for at least one second layer of the first and second plurality of layers of material.

21. prior to the sequential stacking, further comprising removing a portion of the component to form a first surface; 17. The method of claim 16, wherein the sequential stacking of the first plurality of layers of material forms an extension of the first surface, and the sequential stacking of the second plurality of layers of material is on the first surface and on the extension of the first surface.

22. and removing another portion of the component to form a second surface prior to the sequential stacking; The method of claim 21 , wherein the first plurality of sequential layers of material are on the second surface.

23. 23. The method of claim 22, wherein the sequential deposition of the first and second layers of material forms respective stepped edges that meet one another.

24. prior to the sequential stacking, further comprising removing a portion of the component to form a first surface; 24. The method of claim 23, wherein the sequential stacking of the first plurality of layers of material forms a step-like extension of the first surface, and the sequential stacking of the second plurality of layers of material is on the first surface and the step-like extension of the first surface.

25. further comprising removing another portion of the component to form a second surface; 25. The method of claim 24, wherein the first plurality of sequential layers of material is on the second surface.

26. 20. The method of claim 16, wherein the step of sequentially depositing the first and second multiple layers of material includes repeating the step of sequentially depositing the first and second multiple layers of material.

27. The method of claim 16 , wherein the component comprises a turbomachine blade of a turbomachine, and the overhang portion comprises a flared tip rail extending circumferentially relative to an axis of the turbomachine.

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