Method for forming or repairing a component having an overhang and related turbomachinery component

Abstract

The present invention relates to forming or repairing a component having an overhang, and to providing an associated turbomachine blade. In forming or repairing a part having an overhang, a portion is removed and a section is added to the part, the section including the overhang. The adding includes sequentially depositing at least a plurality of layers of material onto the part, the at least a plurality of layers of material approximating dimensions of the section including the overhang. The sequential deposition may include, for example, laser welding, and may be performed in a number of ways to form a transition layer within the overhang. The method may include machining at least one of the plurality of layers of material to form the section including the overhang.

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 components may have sections that overhang other portions of the component. Overhung sections may need to be added during fabrication or repaired after a period of use. One exemplary application includes flared tips for 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 the leading and trailing edges. A flared tip may be joined to the radially outer end of the airfoil and 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 turbomachine blades require two-dimensional buildup of material, either vertically or radially, using, for example, casting or additive manufacture. Flared tip turbomachine blade manufacturing involves adding material both circumferentially and radially. Flared tip turbomachine blades are currently not repairable and are therefore replaced. Other turbomachine hot gas path components and other industrial parts with overhangs present similar challenges. Summary of the Invention

[0003] One aspect of the present disclosure provides a turbomachine component including a body having a first side, a second side, and a longitudinal axis, and an overhang portion extending in an overhanging manner from at least one of the first side and the second side of the body, wherein at least a portion of the overhang portion includes 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 present disclosure relates to a method for adding a section to a part, the section including an overhang, the adding including sequentially depositing multiple layers of material on a surface of the part, the multiple layers of material approximating dimensions of the section including the overhang, and the method including machining the multiple layers of material to form the section including the overhang.

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

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

[0007] Another aspect of the present disclosure provides a turbomachine component including a body having a first side and a second side, and an overhang portion extending in an overhanging manner from at least one of the first side and the second side of the body, wherein at least a portion of the overhang portion includes a first plurality of material layers extending in a first direction and a second plurality of material layers extending in a second direction that is non-planar with respect to the first direction of the first plurality of material layers.

[0008] One aspect of the present disclosure relates to a method including adding a section to a component, the section including an uphanging portion, by sequentially depositing a first plurality of material layers on the component extending in a first direction and sequentially depositing a second plurality of material layers on the component extending in a second direction different from the first direction. The second plurality of material layers mates with the first plurality of material layers, and the first and second plurality of material layers collectively approximate the dimensions of the section including the uphanging portion and are non-planar with respect to each other. The method includes machining the first and second plurality of material layers to form the section including the uphanging portion.

[0009] The exemplary aspects of the present disclosure are designed to solve the problems described herein and / or other problems not discussed. [Brief explanation 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] 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, according to an embodiment of the present disclosure; [Figure 2] FIG. 2 is a cross-sectional view of a compressor section of the gas turbine of FIG. 1. [Figure 3] 2 is a cross-sectional view of the turbine section of the gas turbine of FIG. 1. [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; [Figure 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] 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 material layers on the surface of a component. [Figure 8] FIG. 1 is an enlarged cross-sectional view showing multiple layers of material each made up of a series of weld beads. [Figure 9] FIG. 1 is a schematic plan view showing a series of weld beads on two layers of material extending 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] FIG. 10 is a cross-sectional view of the overhang portion of the flared tip rail shape, including the portion to be removed and the planned removal line. [Figure 12] 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 the 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 stacked on the 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 show how the new overhang is machined. [Figure 15] 7 is a cross-sectional view showing a state in which multiple material layers are sequentially stacked in a first direction on a first surface of the component of FIG. 6. FIG. [Figure 16] FIG. 7 is a cross-sectional view of the part after removing a portion of FIG. 6 and, optionally, creating two surfaces for constructing a new overhang. [Figure 17] FIG. 10 is a cross-sectional view of the part after rotating the part and depositing the first plurality of layers of material. [Figure 18A] FIG. 10 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] FIG. 10 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] 10 is a cross-sectional view of a part after repeated sequential deposition of first and second multiple layers of material onto the part while rotating the part. FIG. [Figure 18D] 1 is a cross-sectional view illustrating sequential non-perpendicular deposition of multiple layers of material onto a part. [Figure 18E] 1 is a cross-sectional view illustrating sequential non-perpendicular deposition of multiple layers of material onto 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. FIG. [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 how multiple layers of material are sequentially stacked in a second direction on a second surface of the component of FIG. 20. FIG. [Figure 22] The portion of FIG. 21 is shown in cross section to show how the new overhang is machined. [Figure 23] 10 is a cross-sectional view of a pair of overhangs in an exemplary section of a double flared tip rail configuration including the portion to be removed and the intended removal line. FIG. [Figure 24] FIG. 10 is a cross-sectional view illustrating an exemplary overhang in the form of an inwardly extending double flared tip rail. [Figure 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 by a predetermined angle to form an angled 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 INVENTION

[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 is understood that each example is provided by way of explanation of the disclosure, and not as a limitation thereof. Indeed, it will be apparent to those 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 with another embodiment to yield a still 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. Particular terminology has been selected to describe the present disclosure and its constituent subsystems and components. Wherever possible, these terms have been selected based on language common to the technical field. 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 comprised of multiple components, and what is referred to herein as including multiple components may be referred to elsewhere as 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 referenced and described components, including the accompanying description and context, and the manner in which the terminology relates to the several figures, and the precise use of the terms in the appended claims. Furthermore, although the following examples are presented in the context of an exemplary application of turbomachine blades that may be used in the compressor or turbine of a gas turbine system, the technology of the present application is also applicable, without limitation, to other categories of turbomachinery, and many other industrial parts, as will be understood by one of ordinary skill in the relevant art.

[0013] Given the nature of gas turbine operation, 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 both 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 properly be 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 a 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 can be used to indicate a direction of movement or a relative position along the central axis of the engine. As noted above, these terms can 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 facing 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). Using a major subsystem such as a turbine as another example (and assuming a typical gas turbine arrangement such as that 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 refer to a location within a given conduit or flow passage relative to the direction of fluid movement within the given conduit or flow passage (hereinafter referred to as the "flow direction"). 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 direction of flow through the conduit during normal or expected operation. Given the configuration of gas turbines, particularly the arrangement of the compressor and turbine sections relative to 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 commonly used herein. In this regard, the term "radial" will be understood to refer to movement or location perpendicular to the axis. In this context, it may be necessary to describe relative distance from the central axis. In such cases, for example, if a first component is closer to the central axis than a second component, the first component may be described as either "radially inward" or "inboard" of the second component. On the other hand, if the first component resides 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 position parallel to the axis, and the term "circumferential" refers to movement or position around the axis. Unless otherwise stated 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 claiming attributes of non-integral components, such as rotor or stator blades, that function therein.

[0016] The term "turbomachine blade" or "blade," without further specification, refers to a rotating blade of either a compressor or a turbine, and thus may include both compressor rotor blades and turbine rotor blades, and also refers to a stationary blade of either a compressor or a turbine, and thus may include both compressor stator blades and turbine stator blades. The term "blade" may be used generically 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] Additionally, 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 denote the 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 dictates otherwise. As used herein, it will be further understood that 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 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 as well as instances in which it does not occur or is not present.

[0019] When an element or layer is referred to as "being," "engaging," "connecting," or "coupled" to another element or layer, it can 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 be no intervening elements or layers present. 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 exemplary gas turbines according to 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. Generally, gas turbines operate by extracting energy from a pressurized flow of hot gas produced by the combustion of a fuel in a stream 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, each 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, although more or fewer may be present. Each stage may include a plurality of turbine nozzles (i.e., stator blades) 24 that remain stationary during operation, followed by a plurality 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 within the working fluid flowpath is indicated by arrows.

[0022] In one example of the operation of the gas turbine 10, rotation of the compressor rotor blades 20 within the axial compressor 12 may compress a flow of air. Energy may be released when the compressed air is mixed with fuel and ignited in the combustor 16. The resulting flow of hot gases, or working fluid, from the combustor 16 is then directed onto the turbine rotor blades 26, inducing 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 rotation of the compressor rotor blades 20 to generate a required supply of compressed air and / or may be used, for example, in a generator to generate electricity.

[0023] For background purposes, Figure 4 shows a perspective view of an exemplary component 28 having an overhang 30. For purposes of illustration, the component 28 is depicted as a flare tip turbomachine blade 25, and more particularly, 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, for example, a dovetail 32 configured for attachment to a corresponding dovetail slot in the periphery of the rotor disk. 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 the active component of the turbine bucket 26 that intercepts the flow of working fluid through the turbine 14 to induce 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 the flow path of the working fluid through the turbine 14.

[0025] The 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 the 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. It should be understood that in such cases, 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 the forward end of the turbine 14, where the working fluid enters the turbine 14 from the combustor 16, and the aft end of the turbine 14, where the working fluid exits the turbine 14. The direction of rotation may be defined relative to the 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 for forming or repairing a component 28 having an overhang 30, such as a flared tip of a turbomachine blade 25. For repair purposes, the method can include removing and adding a portion to the component. For purposes of initially forming the component 28, the method can add a section to an already formed portion of the component 28. In either case, the added or formed section includes the overhang. Adding includes sequentially layering one or more layers of material onto the component. When completed, the layers of material approximate the dimensions of the section, including the overhang. Sequential deposition can be accomplished by numerous methods of forming varied 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 part 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] FIG. 5 is an enlarged cross-sectional view of a component 28 having a body 60 with 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 positioned in the gas turbine 10 ( FIG. 1 ). The overhanging portion 30 extends overhangingly 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, component 28 includes turbomachine blade 25 that includes, for example, a flare tip rail 70 that overhangs blade suction face 44 at first side 62. Thus, flare tip rail 70 is an example of an overhang portion 30 ( FIG. 4 ) of component 28. Body 60 includes airfoil 40, with flare tip rail 70 opposing opposing member 66 in the form of a radially extending tip rail 134 extending from the end of airfoil 40. Flare tip rail 70 extends circumferentially relative to axis 18 ( FIG. 1 ) of gas turbine 10. In other embodiments, overhang portion 30 may be opposed by another overhang portion, such as flare tip rail 70, which may or may not have a different mass and may extend around the periphery of airfoil 40 (see, for example, FIGS. 23 and 24 ).

[0029] The damaged overhanging portion can include an overhanging flared tip rail 70, i.e., an overhanging flared tip rail lacking structural support. Portion 72 can include any structure desired to be removed and can include an undamaged portion or a portion having various damage, including but not limited to, a worn surface, cracks, openings, roughness, etc. In this situation, as shown in FIG. 6 , portion 72 can be removed from part 28 to form surface 74 on the part, e.g., turbomachine blade 25. Portion 72 can 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 can be removed using any now known or later developed technique, including, but not limited to, electrical discharge machining (EDM), mechanical cutting / grinding, laser cutting, etc. 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 can reshape the removed portion. Surface 74 may be flat, curved, or have a three-dimensional shape or profile. 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, rotating the part 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 removing at most half of portion 72. In another non-limiting example, more than half of flared tip rail 70 is removed, e.g., based on removing at least half of portion 72.

[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 technique appropriate 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., 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 can be formed by material removal through machining, with little or no additional material addition. The addition of material layer 82 can be provided in a number of ways. For example, material layers 82 can 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 on part 28 includes forming a series of weld beads 84 to form each layer 82. Any number of weld beads 84 can be used to form a layer. The layers can be formed using any pattern of welds, such as a continuous spiral weld bead starting from the center or periphery, or side-by-side individual linear weld beads extending from side to side across 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 of material layers 82 80 are used. Here, second ends 90 of the plurality of material layers 82 are arranged in a stepped manner to approximate the dimensions of the overhang (to be formed). In one example, a first end 86 of the single plurality of material layers 82 is shown generally aligned with a surface 88 of the part 28, and a second end 90 of the single plurality of material layers 82 extends in a stepped manner to approximate the dimensions of 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, moving 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 material layers 82 may not be precisely aligned 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 part 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 material layers 82. Any angle can be employed to foster strength in the new section 76 ( FIG. 10 ). In addition to weld bead direction, sequential layering can be performed in a manner that controls local temperature of the structure to prevent thermal cracking. For example, a user can hop from location to location on the build surface 74 to allow cooling in one area while working in another area and ensure that a new weld bead is applied in the cooled location before applying the new weld bead.

[0034] FIG. 10 illustrates portion 28 after machining multiple 80 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 lifespan. Machining may include any manner of material removal that allows for a blending of surfaces to yield 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 mentioned, body 60 may include an airfoil 40 of a 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 the radially-facing outer surface 138 of the overhang portion 78 parallel to the axis 18 of the turbomachine.

[0035] 7 , surface 74 is formed to be parallel to radially-facing outer surface 92 of new section 76, perhaps extending parallel to axis 18 ( FIG. 1 ) of gas turbine 10 ( FIG. 1 ). In other words, surface 74 extends perpendicular to longitudinal axis 75 of the part, or, in terms of a turbomachine blade, radial axis 75 of body 60 of airfoil 40. As a result, part 28 includes at least a portion of overhang portion 78 including multiple 80 layers of material 82, each layer of material 82 extending at an angle perpendicular to longitudinal axis 75 of body 60. The portion of overhang portion 78 may include at most half of overhang portion 78 extending from floor 136 to the radially-facing outer surface of overhang portion 78 (when blade is installed), or more than half of overhang portion 78. In an alternative embodiment, part 28 may be rotated so that surface 74 is inclined from 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 part 28 is rotated from vertical by the rotation angle θ1. FIG. 26 is a cross-sectional view of adding a new section 76 to 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 part 28, i.e., on 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 with a 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 beveling 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, an 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 ). Furthermore, surface 94 will be at an angle that is neither perpendicular nor parallel to the target radially-facing outer flat surface 96 ( FIG. 14 ) of new overhang portion 78, i.e., new flare tip rail, of the final product.

[0037] As shown in FIG. 13A , 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 , part 28 can be rotated to position surface 94 at an angle β other than horizontal and vertical before sequentially depositing the plurality 80 of material layers 82. Part 28 may alternatively be rotated to the position of FIG. 13B after a certain number of material layers 82 have been sequentially deposited. Angle β can be any angle that allows for a desired stepping of the plurality 80 of material layers 82, i.e., not substantially horizontal as defined herein. For example, angle β can be such that end 98 of layer 82 steps outward in a manner that allows the end to be later machined to align with surface 88, and end 100 of layer 82 steps outward in a manner that forms a new overhang portion 78 of part 28. Angle β can enable the formation of an overhang portion 78 with an extent that would not be formed if 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 deposition of layers without allowing for undesired formation, for example, in the form of dripping, slumping, or breaking.

[0038] 13A-B also illustrate sequentially depositing the plurality of 80 layers of material 82 onto the surface 94. In this case, each end 98, 100 of the layers 82 may be stepped. That is, as shown in FIGS. 13A-B, sequentially depositing 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 and second ends (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, as previously described, 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. Here, as shown in phantom lines in FIG. 14 , after machining, the layer 82 of the new overhang portion 78 of the finished product extends at an acute angle α relative to the axis 18 (shown schematically in phantom lines) of the gas turbine 10 ( FIG. 1 ), at an acute angle α relative to a target surface 96 ( FIG. 14 ), and at an acute angle δ relative to the longitudinal axis 75 of the body 60 or component 28 (i.e., the radial axis 75 of the airfoil 40). Furthermore, the target surface 96, when completed, is at an angle α relative to the plurality 80 layers of material 82 and the surface 94 upon which the layers will be built. While the target surface 96 is shown as a planar surface, it should be understood that 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 layers of material 82 to form the overhang portion 78 and the target outer flat surface 138. The target outer (flat) surface 96 is at an angle α relative to the plurality 80 layers of material 82. The turbomachine 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 portion 76 extends in an overhanging manner 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 portion extending from both sides. As noted in FIG. 14, at least a portion of the overhang portion 78 includes the plurality 80 layers of material 82, each layer of material 82 extending at an acute angle δ relative 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 the radially facing outer surface 138 of the overhang portion 78 may be parallel to the turbomachine axis 18 when in the operating position.

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

[0041] As shown in FIGS. 6 and 15 , when applied to a used part, any portion 72 of the part 28 can be removed to form the surface 74. Otherwise, the formation of the new section 76 can be from an initially formed part, as shown in FIG. 6 . In one embodiment, as shown in FIG. 15 , adding the section 76 to the part 28 including the overhang portion 78 can include sequentially depositing a first plurality 110 of material layers 82 onto the part 28 extending 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 can be sequentially formed horizontally on the part 28 in a manner that consumes a portion 112 ( FIG. 6 ) of the flared tip rail 70. Alternatively, as shown in FIG. 16 , any desired material, such as the portion 112 ( FIG. 6 ) of the flared tip rail 70, can 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 rotation, layers 82 may be sequentially formed horizontally on part 28 on surface 114, i.e., without consuming any other material. In this configuration, sequential stacking of first plurality 110 of material layers 82 rests on surface 114, forming an extension 116 of surface 114. Edges 118 of layers 82 ideally align with surface 74 as formed, but if not, can be machined to align with surface 74. In FIG. 15 , sequential stacking of first plurality 110 of material layers 82 forms extension 116 of surface 74. As described herein, alternative embodiments may form extensions with stepped edges (see, e.g., FIGS. 18C and 19 ).

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

[0043] 18A-18E illustrate 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 explained, 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 illustrate embodiments 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 illustrates an alternative embodiment in which the plurality of material layers 110, 120 are reversed in position. That is, second plurality 120 of layers of material 82 is first formed on surface 74 to provide extension 116. Part 28 is then rotated such that surface 114 and extension 116 are configurable 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 to form extension 116.

[0044] 18C illustrates another alternative embodiment of the part after repeated sequential layering of each plurality. In other words, fewer than all of the material layers 82 in 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 in 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 in 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] 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. Here, 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 desirable bonding of the layers and accommodate hardware welding constraints. FIG. 18D shows surfaces 74, 114 at an obtuse angle γ (90°<γ<180°), while FIG. 18E shows surfaces 74, 114 at an angle γ greater than 180°.

[0046] 19-21 illustrate an alternative embodiment substantially similar to that 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 deposition of a 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 deposition of a second plurality 120 of material layers 82 over surface 74 and the stair-stepped extension 122 of surface 74 (FIG. 20). More specifically, the sequential deposition of the second plurality 120 of material layers 82 over surface 74 is performed to generally mate 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 pluralities 110, 120 of material layers 82 can have mating stair-stepped ends or generally mating stair-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] FIG. 22 shows part 28 after machining multiple 110, 120 of layers of material 82 to form section 76 including new overhang portion 78. This process can follow any of the described processes for sequentially stacking multiple layers of material. This machining process can be as described in connection with FIG. 10. While machining is shown performed from the embodiment of FIG. 21, it will be appreciated that similar machining may be performed on the embodiments 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] FIG. 23 is an enlarged cross-sectional view of a component 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, overhanging portions 30, 230 extend overhangingly from the first side 62 and the second side 64 of the body 60, respectively. Both overhanging portions 30, 230 lack vertical structural support along portions thereof. 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 component 28 includes a turbomachine blade 25 including flared tip rails 70, 270 that overhang the suction face 44 and pressure face 42 of the blade, for example. However, it should be noted that the flared tip rails 70 may extend around the entire tip of the airfoil 40. Thus, the flare tip rail 70 is an 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 can be repeated as many times as necessary and with as many build surfaces 74, 94, 114, 116 as necessary. Any number of portions 72 (damaged overhang portions) can 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 outward relative to the body 60 of the airfoil 40. In FIG. 24, overhang portions 330, 430 extend inwardly from the first side 62 and the second side 64 of the body 60, respectively. Both overhang portions 330, 430 lack vertical structural support at portions 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. While 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 numerous superior physical properties compared to conventional alloys, including, but not limited to, high mechanical strength and high thermal creep deformation resistance, such as Rene N5, Rene N500, Rene 108, CM247, Haynes alloy, Inconel, MP98T, TMS alloy, and CMSX single crystal alloy. In one embodiment, superalloys that may find the teachings of the present disclosure particularly advantageous are those 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 from the rest of the component 28. That is, the component 28 includes a first metal, and the plurality 80, 110, 120 of the material layer 82 include a second metal that is different from the first metal. Thus, the new section 76 may be a homogeneous material. Alternatively, different layers 82 of the plurality 80, 110, 120 of material layers 82 may be different, such that new section 76 has different materials therein. That is, 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 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, while 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 including a second metal different from the first metal. FIGS. 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 novel 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., the 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 novel 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 novel 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 turbomachine axis 18 (FIG. 1). It should also be noted that the overhangs 30, 230, 330, 430 may take the form of a single unitary overhang extending 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 136 to the radially-facing outer surface 201, i.e., based on at most half of the removed portion 72. As shown in FIG. 14 , in one embodiment, it is contemplated that each layer of material 82 extends at an acute angle δ relative to the radial axis 75 of the body 60 and at an acute angle α relative 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 surfaces 94 formed with the material layers 82 of the plurality 80 of the novel flare tip rail 132 may extend at an acute angle α relative to the shaft 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 material layers 82 thereof 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 edges ( FIG. 22 ), or may have generally mating stepped edges 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 can be substantially perpendicular, i.e., 90° + / - 2°. FIGS. 18D-E illustrate 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 including a first metal and at least one second material layer therein including a second metal different from the first metal. That is, different materials may be used within a given plurality of material layers. For example, the layer 82 of the new section 76 near the surface 74 may match the material of the part 28, while 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, which 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 involved in 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, for example, on the acts involved. Those skilled in the art will also recognize that additional steps describing the processes may be added.

[0059] Approximate language used throughout this specification and claims can be applied to modify any permissible quantitative expression without resulting in a change in the basic function to which it relates. Thus, values ​​modified by terms such as "about," "approximately," and "substantially" should not be limited to the exact value specified. In at least some instances, approximating language can correspond to the precision of the instrument used to measure the value. Throughout this 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," as 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 used to measure the value.

[0060] Corresponding structure, materials, acts, and equivalents of all means- or step-plus-function elements in the following claims are intended to include any structure, material, or acts for performing that 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 were chosen and described in order to best explain the principles and practical applications of the disclosure and to enable others skilled in the art to understand the disclosure in various embodiments with various modifications as suited to the particular uses contemplated. [Explanation of symbols]

[0061] 10: Gas turbine 12: Compressor 14: Turbine 16: Combustor 18: Center shaft 20: Compressor rotor blade 22: Compressor stator blade 24: Turbine nozzle 25: Flare tip turbomachine blade 26: Turbine bucket 28: Component 30: Overhang portion 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 portion 80: Multiple material layers 82: Material layer 83: Void 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 material layers 114: Surface 116: Extension 120: Second plurality of material layers 122: Stepped extension 130: Turbomachinery component 132: Flared tip rail 134: Tip rail 136: Floor 138: Radially facing outer surface 230: Overhang

Claims

1. adding a section to a part (28), the section including an overhang (78) lacking structural support in a portion thereof; positioning a second surface (114) of the component (28) substantially horizontal; sequentially depositing a first plurality of material layers (110) on a second surface (114) extending in a first direction; rotating the part (28) so that a first surface (74) of the part (28) is positioned substantially horizontally; sequentially depositing a second plurality of layers of material (120) on a first surface (74) of the component (28) 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 (110), the first plurality of layers of material and the second plurality of layers of material (110, 120) collectively approximating the dimensions of a section including an overhang portion (78) and being non-planar with respect to one another; processing the first and second layers of material (110, 120) to form a section including an overhang (78); A method comprising:

2. 2. The method of claim 1, wherein the component (28) comprises a first metal and at least one material layer (82) of the first plurality of material layers (110) and the second plurality of material layers (120) comprises a second metal different from the first metal.

3. 3. The method of claim 1 or 2, wherein at least one of the first plurality of material layers (110) and the second plurality of material layers (120) comprises at least one first material layer (82) including a first metal and at least one second material layer (82) including a second metal different from the first metal.

4. 4. The method of claim 1, wherein the step of sequentially depositing a first plurality of layers of material (110) and a second plurality of layers of material (120) on the component (28) includes forming a series of weld beads (84) to form each layer of material (82).

5. 5. The method of claim 4, wherein a series of weld beads (84) for at least one first layer (82) of the first plurality of layers of material (110) and the second plurality of layers of material (120) is at a non-parallel angle relative to a series of weld beads for at least one second layer (82) of the first plurality of layers of material (110) and the second plurality of layers of material (120).

6. prior to the sequential lamination, removing a portion (72) of the component (28) to form a first surface (74); 2. The method of claim 1, wherein the sequential stacking of the first plurality of layers of material (110) forms an extension of the first surface (74) and the sequential stacking of the second plurality of layers of material (120) is on the first surface and on the extension of the first surface (74).

7. The method of claim 6, further comprising removing another portion (112) of the component (28) to form a second surface (114) prior to the sequential stacking.

8. The method of claim 7, wherein the first and second plurality of layers of material (110, 120) extend to a greater extent relative to the previous layer of material (82) to form mating stepped edges.

9. prior to the sequential lamination, removing a portion (72) of the component (28) to form a first surface (74); 2. The method of claim 1, wherein the sequential stacking of the first plurality of layers of material (110) forms a stepped extension (122) of the first surface (74), and the sequential stacking of the second plurality of layers of material (120) is on the first surface (74) and on the stepped extension (122) of the first surface (74).

10. The method of claim 9, further comprising removing another portion (112) of the part (28) to form a second surface (118).

11. 2. The method of claim 1, wherein the step of sequentially stacking the first and second multiple material layers (110) and (120) comprises the steps of: sequentially stacking the first and second multiple material layers (110) and (120), rotating the part (28) to position the first surface (74) or the second surface (114) substantially horizontally, and repeating the sequential stacking of the second multiple material layers (120).

12. 2. The method of claim 1, wherein the component (28) comprises a turbomachine blade (25) of the turbomachine (10), and the overhang portion (78) comprises a flared tip rail (132) extending circumferentially relative to an axis (18) of the turbomachine (10).

13. removing a portion (72) of the component (28) to form a first surface (74); removing another portion (112) of the part (28) to form a second surface (114); Including, The step of adding a section to the part (28) further comprises: sequentially depositing a first plurality of layers of material (110) on a second surface (114) extending in a first direction such that the first plurality of layers of material (110) form a stepped extension (122) of the first surface (74); and sequentially depositing a second plurality of layers of material (120) on the first surface (74) and the stepped extension (122) of the first surface (74).

Images