COMPONENTS AND METHODS FOR FORMING COMPONENTS - Patent application

Abstract

PROBLEM TO BE SOLVED: To provide a cooling component including a channel and an insert, and a method of forming the cooling component, which are new and improved.SOLUTION: A component (201) including a channel (301) and an insert (304) is provided. The channel (301) is configured to extend through a wall thickness (202) of the component (201) from an inner surface (203) of the component (201) to an outer surface (204) of the component (201). The channel (301) is defined by an inner channel surface (302). The insert (304) is configured to permit a flow of cooling fluid such as air and has an outer insert surface (305) corresponding to and attached to the inner channel surface (302). The component (201) may be a turbine component (201). Also provided is a method for forming the component (201).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention is directed generally to cooling components and methods of forming cooling components. More specifically, the present invention is directed to cooling components including a flow channel and an insert, and methods of forming cooling components. [Background technology]

[0002] To increase both power output and efficiency, modern gas turbine power plants utilize ever-increasing turbine inlet temperatures. Unfortunately, these high temperatures jeopardize the integrity of turbine components. Both convection and film cooling can be used to protect turbine components from high temperatures.

[0003] The turbine vane and blade cooling art discloses various configurations for increasing the effectiveness of film cooling and reducing the amount of cooling air required to increase the overall efficiency of the engine while obtaining a suitable service life for the vanes and blades. For example, typical vane and blade airfoils in the high pressure turbine section of an engine include cooling holes through the pressure side, suction side, or both, to project a film of cooling air along the exterior surface of the airfoil to provide film cooling in a conventional manner.

[0004] The effectiveness of film cooling depends on many factors. Hole length is one such factor. Film cooling effectiveness is proportional to the hole length. However, thin wall designs to enhance both convection and film cooling effectiveness can present challenges as they limit the hole length. Summary of the Invention

[0005] In an exemplary embodiment, a component is provided that includes a flow channel and an insert, the flow channel being configured to penetrate a wall thickness of the component from an inner surface of the component to an outer surface of the component and defined by an inner flow channel surface, and the insert being configured to permit the flow of a cooling fluid and having an insert outer surface conforming to and attached to the inner flow channel surface.

[0006] In another exemplary embodiment, a turbine component is provided that includes a flow passage and an insert. The flow passage is configured to penetrate a wall thickness of the component from an inner surface of the component to an outer surface of the component and is defined by a flow passage inner surface. The insert is configured to allow the flow of a cooling fluid and has an insert outer surface that conforms to and is attached to the flow passage inner surface. The insert has a protruding portion that protrudes from the inner surface of the turbine component.

[0007] In yet another exemplary embodiment, a method for forming a component is provided. The method includes forming a channel configured to penetrate a wall thickness of the component from an inner surface of the component to an outer surface of the component. The channel is defined by an inner channel surface. The method further includes forming an insert. The method further includes attaching the insert to the inner channel surface. The insert is configured to allow the flow of a cooling fluid.

[0008] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, which illustrates, by way of example, the principles of the invention. [Brief explanation of the drawings]

[0009] [Figure 1] 1 shows a flow chart for forming a part according to the method of the present disclosure. [Figure 2] 1 illustrates a perspective view of a turbine nozzle casting according to an embodiment of the present disclosure. [Figure 3] 10A-10C schematically illustrate a method for forming a part having an insert configured to form a cylindrical flow channel, according to an embodiment of the present disclosure. [Figure 4]10A-10C schematically illustrate a method for forming a part having an insert configured to result in a fan-shaped flow path, according to an embodiment of the present disclosure. [Figure 5] 10A-10C schematically illustrate a method for forming a part having an insert configured to form a laid-back fan-shaped flow channel, according to an embodiment of the present disclosure. [Figure 6] 6 shows a cross-sectional view taken along line 6-6 in FIG. 2, viewed in the direction of the arrows in the figure. [Figure 7] 7 shows a cross-sectional view taken along line 7-7 in FIG. 2, viewed in the direction of the arrows in the figure. DETAILED DESCRIPTION OF THE INVENTION

[0010] The following detailed description, taken in conjunction with the accompanying drawings in which like numerals refer to like elements, is intended to describe various embodiments of the disclosed subject matter and is not intended to represent the only embodiment. Each embodiment described in this disclosure is presented merely as an example or illustration and should not be construed as preferred or advantageous over other embodiments. The examples presented herein are not intended to be exhaustive or to limit the claimed subject matter to the precise form disclosed.

[0011] Exemplary parts and methods of forming parts are provided. Embodiments of the present disclosure enable reduced cooling air usage, reduced part weight, reduced low cycle fatigue, and increased part life compared to parts and methods that do not utilize one or more features disclosed herein.

[0012] All numbers expressing quantities of ingredients and / or reaction conditions, unless otherwise specified, should be understood as being modified in all instances by the term "about."

[0013] All percentages and ratios are calculated by weight unless otherwise specified. All percentages are calculated based on the total weight of the composition unless otherwise specified. All ingredient or composition levels refer to the effective level of that ingredient or composition and exclude impurities, such as residual solvents or by-products, that may be present in commercially available materials.

[0014] As used herein, the articles "a" and "an" mean one or more when applied to any feature of the embodiments of the invention described in the specification and claims. The use of "a" and "an" does not limit the meaning to a single feature unless specifically stated to do so. The article "the" before singular or plural nouns or noun phrases indicates one or more specifically identified features and may have the meaning of singular or plural depending on the context in which it is used. The adjective "any" means one, some, or all, regardless of quantity.

[0015] As used herein, the term "at least one" means one or more and thus includes individual parts and mixtures / combinations.

[0016] As used in this specification, the term "comprises" (and grammatical variations thereof) is used in the inclusive sense of "having" or "including" and not in the exclusive sense of "consisting only of."

[0017] In accordance with the present disclosure, the present invention can include components including a flow passage and an insert. The components shown herein can include a metal or alloy. In some embodiments, the alloy can include an HTW alloy. As used herein, the term "HTW alloy" refers to an alloy that exhibits liquation and high-temperature strain age cracking, making it impractical to weld. In further embodiments, the HTW alloy is a superalloy. As used herein, the term "superalloy" is used as commonly used in the art, i.e., to refer to an alloy that has good mechanical strength and high-temperature creep resistance, as well as high corrosion and oxidation resistance.

[0018] In some embodiments, the superalloy may include a nickel-based superalloy, a cobalt-based superalloy, an iron-based superalloy, a titanium-based superalloy, or a combination thereof. Superalloys include, but are not limited to, GTD111, GTD222, GTD444, GTD262, Mar M247, IN 100, IN 738, Rene 80, IN 939, Rene N2, Rene N4, Rene N5, Rene N6, Rene 65, Rene 77 (Udimet700), Rene 80, Rene 88DT, Rene 104, Rene 108, Rene 125, Rene 142, Rene 195, Rene N500, Rene N515, IN 706, Nimonic 263, CM247, MarM247, CMSX-4, MGA1400, MGA2400, INCONEL 700, INCONEL 738, INCONEL 792, DSSiemet, CMSX10, PWA1480, PWA1483, PWA1484, TMS-75, TMS-82, Mar-M-200, UDIMET 500, ASTROLOY, etc., and materials selected from the group consisting of Hastelloy, Inconel alloys, Waspaloy, Rene alloys, and combinations thereof.

[0019] As used herein, "ASTROLOY" refers to an alloy having a composition, by weight, of about 15% chromium, about 17% cobalt, about 5.3% molybdenum, about 4% aluminum, about 3.5% titanium, and the balance nickel.

[0020] As used herein, "DS Siemet" refers to an alloy having a composition, by weight, of about 9% cobalt, about 12.1% chromium, about 3.6% aluminum, about 4% titanium, about 5.2% tantalum, about 3.7% tungsten, about 1.8% molybdenum, and the balance nickel.

[0021] As used herein, "GTD111" refers to an alloy having a composition, by weight, of about 14% chromium, about 9.5% cobalt, about 3.8% tungsten, about 4.9% titanium, about 3% aluminum, about 0.1% iron, about 2.8% tantalum, about 1.6% molybdenum, about 0.1% carbon, and the balance nickel.

[0022] As used herein, "GTD262" refers to an alloy having a composition, by weight, of about 22.5% chromium, about 19% cobalt, about 2% tungsten, about 1.35% niobium, about 2.3% titanium, about 1.7% aluminum, about 0.1% carbon, and the balance nickel.

[0023] As used herein, "GTD444" refers to an alloy having a composition, by weight, of about 7.5% cobalt, about 0.2% iron, about 9.75% chromium, about 4.2% aluminum, about 3.5% titanium, about 4.8% tantalum, about 6% tungsten, about 1.5% molybdenum, about 0.5% niobium, about 0.2% silicon, about 0.15% hafnium, and the balance nickel.

[0024] As used herein, "MGA1400" refers to an alloy having a composition, by weight, of about 10% cobalt, about 14% chromium, about 4% aluminum, about 2.7% titanium, about 4.7% tantalum, about 4.3% tungsten, about 1.5% molybdenum, about 0.1% carbon, and the balance nickel.

[0025] As used herein, "MGA2400" refers to an alloy having a composition, by weight, of about 19% cobalt, about 19% chromium, about 1.9% aluminum, about 3.7% titanium, about 1.4% tantalum, about 6% tungsten, about 1% niobium, about 0.1% carbon, and the balance nickel.

[0026] As used herein, "PMA 1480" refers to an alloy having a composition, by weight, of about 10% chromium, about 5% cobalt, about 5% aluminum, about 1.5% titanium, about 12% tantalum, about 4% tungsten, and the balance nickel.

[0027] As used herein, "PWA1483" refers to an alloy having a composition, by weight, of about 9% cobalt, about 12.2% chromium, about 3.6% aluminum, about 4.1% titanium, about 5% tantalum, about 3.8% tungsten, about 1.9% molybdenum, and the balance nickel.

[0028] As used herein, "PMA 1484" refers to an alloy having a composition, by weight, of about 5% chromium, about 10% cobalt, about 2% molybdenum, about 5.6% aluminum, about 9% tantalum, about 6% tungsten, and the balance nickel.

[0029] As used herein, "Rene N2" refers to an alloy having a composition, by weight, of about 7.5% cobalt, about 13% chromium, about 6.6% aluminum, about 5% tantalum, about 3.8% tungsten, about 1.6% rhenium, about 0.15% hafnium, and the balance nickel.

[0030] As used herein, "Rene N4" refers to an alloy having a composition, by weight, of about 9.75% chromium, about 7.5% cobalt, about 4.2% aluminum, about 3.5% titanium, about 1.5% molybdenum, about 6.0% tungsten, about 4.8% tantalum, about 0.5% niobium, about 0.15% hafnium, and the balance nickel.

[0031] As used herein, "Rene N5" refers to an alloy having a composition, by weight, of about 7.5% cobalt, about 7.0% chromium, about 6.5% tantalum, about 6.2% aluminum, about 5.0% tungsten, about 3.0% rhenium, about 1.5% molybdenum, about 0.15% hafnium, and the balance nickel.

[0032] As used herein, "Rene N6" refers to an alloy having a composition, by weight, of about 12.5% ​​cobalt, about 4.2% chromium, about 7.2% tantalum, about 5.75% aluminum, about 6% tungsten, about 5.4% rhenium, about 1.4% molybdenum, about 0.15% hafnium, and the balance nickel.

[0033] As used herein, "Rene 65" refers to an alloy having a composition, by weight, of about 13% cobalt, up to about 1.2% iron, about 16% chromium, about 2.1% aluminum, about 3.75% titanium, about 4% tungsten, about 4% molybdenum, about 0.7% niobium, up to about 0.15% manganese, and the balance nickel.

[0034] As used herein, "Rene 77 (Udimet 700)" refers to an alloy having a composition, by weight, of about 15% chromium, about 17% cobalt, about 5.3% molybdenum, about 3.35% titanium, about 4.2% aluminum, and the balance nickel.

[0035] As used herein, "Rene 80" refers to an alloy having a composition, by weight, of about 14% chromium, about 9.5% cobalt, about 4% molybdenum, about 3% aluminum, about 5% titanium, about 4% tungsten, about 0.17% carbon, and the balance nickel.

[0036] As used herein, "Rene 88DT" refers to an alloy having a composition, by weight, of about 16% chromium, about 13% cobalt, about 4% molybdenum, about 0.7% niobium, about 2.1% aluminum, about 3.7% titanium, about 4% tungsten, about 0.1% rhenium, a maximum of about 4.3% rhenium and tungsten, and the balance nickel.

[0037] As used herein, "Rene 104" refers to an alloy having a composition, by weight, of about 13.1% chromium, about 18.2% cobalt, about 3.8% molybdenum, about 1.9% tungsten, about 1.4% niobium, about 3.5% aluminum, about 3.5% titanium, about 2.7% tantalum, and the balance nickel.

[0038] As used herein, "Rene 108" refers to an alloy having a composition, by weight, of about 8.4% chromium, about 9.5% cobalt, about 5.5% aluminum, about 0.7% titanium, about 9.5% tungsten, about 0.5% molybdenum, about 3% tantalum, about 1.5% hafnium, and the balance nickel.

[0039] As used herein, "Rene 125" refers to an alloy having a composition, by weight, of about 8.5% chromium, about 10% cobalt, about 4.8% aluminum, up to about 2.5% titanium, about 8% tungsten, up to about 2% molybdenum, about 3.8% tantalum, about 1.4% hafnium, about 0.11% carbon, and the balance nickel.

[0040] As used herein, "Rene 142" refers to an alloy having a composition, by weight, of about 6.8% chromium, about 12% cobalt, about 6.1% aluminum, about 4.9% tungsten, about 1.5% molybdenum, about 2.8% rhenium, about 6.4% tantalum, about 1.5% hafnium, and the balance nickel.

[0041] As used herein, "Rene 195" refers to an alloy having a composition, by weight, of about 7.6% chromium, about 3.1% cobalt, about 7.8% aluminum, about 5.5% tantalum, about 0.1% molybdenum, about 3.9% tungsten, about 1.7% rhenium, about 0.15% hafnium, and the balance nickel.

[0042] As used herein, "Rene N500" refers to an alloy having a composition, by weight, of about 7.5% cobalt, about 0.2% iron, about 6% chromium, about 6.25% aluminum, about 6.5% tantalum, about 6.25% tungsten, about 1.5% molybdenum, about 0.15% hafnium, and the balance nickel.

[0043] As used herein, "Rene N515" refers to an alloy having a composition, by weight, of about 7.5% cobalt, about 0.2% iron, about 6% chromium, about 6.25% aluminum, about 6.5% tantalum, about 6.25% tungsten, about 2% molybdenum, about 0.1% niobium, about 1.5% rhenium, about 0.6% hafnium, and the balance nickel.

[0044] As used herein, "MarM247" and "CM247" refer to alloys having a composition, by weight, of about 5.5% aluminum, about 0.15% carbon, about 8.25% chromium, about 10% cobalt, about 10% tungsten, about 0.7% molybdenum, about 0.5% iron, about 1% titanium, about 3% tantalum, about 1.5% hafnium, and the balance nickel.

[0045] As used herein, "IN100" refers to an alloy having a composition, by weight, of about 10% chromium, about 15% cobalt, about 3% molybdenum, about 4.7% titanium, about 5.5% aluminum, about 0.18% carbon, and the balance nickel.

[0046] As used herein, "INCONEL 700" refers to an alloy having a composition, by weight, of about 0.12% maximum carbon, about 15% chromium, about 28.5% cobalt, about 3.75% molybdenum, about 2.2% titanium, about 3% aluminum, about 0.7% iron, about 0.3% maximum silicon, about 0.1% maximum manganese, and the balance nickel.

[0047] As used herein, "INCONEL 738" refers to an alloy having a composition, by weight, of about 0.17% carbon, about 16% chromium, about 8.5% cobalt, about 1.75% molybdenum, about 2.6% tungsten, about 3.4% titanium, about 3.4% aluminum, about 0.1% zirconium, about 2% niobium, and the balance nickel.

[0048] As used herein, "INCONEL 792" refers to an alloy having a composition, by weight, of about 12.4% chromium, about 9% cobalt, about 1.9% molybdenum, about 3.8% tungsten, about 3.9% tantalum, about 3.1% aluminum, about 4.5% titanium, about 0.12% carbon, about 0.1% zirconium, and the balance nickel.

[0049] As used herein, "UDIMET 500" refers to an alloy having a composition, by weight, of about 18.5% chromium, about 18.5% cobalt, about 4% molybdenum, about 3% titanium, about 3% aluminum, and the balance nickel.

[0050] As used herein, "Mar-M-200" refers to an alloy having a composition, by weight, of about 9% chromium, about 10% cobalt, about 12.5% ​​tungsten, about 1% niobium, about 5% aluminum, about 2% titanium, about 10.14% carbon, about 1.8% hafnium, and the balance nickel.

[0051] As used herein, "TMS-75" refers to an alloy having a composition, by weight, of about 3% chromium, about 12% cobalt, about 2% molybdenum, about 6% tungsten, about 6% aluminum, about 6% tantalum, about 5% rhenium, about 0.1% hafnium, and the balance nickel.

[0052] As used herein, "TMS-82" refers to an alloy having a composition, by weight, of about 4.9% chromium, about 7.8% cobalt, about 1.9% molybdenum, about 2.4% rhenium, about 8.7% tungsten, about 5.3% aluminum, about 0.5% titanium, about 6% tantalum, about 0.1% hafnium, and the balance nickel.

[0053] As used herein, "CMSX-4" refers to an alloy having a composition, by weight, of about 6.4% chromium, about 9.6% cobalt, about 0.6% molybdenum, about 6.4% tungsten, about 5.6% aluminum, about 1.0% titanium, about 6.5% tantalum, about 3% rhenium, about 0.1% hafnium, and the balance nickel.

[0054] As used herein, "CMSX-10" refers to an alloy having a composition, by weight, of about 2% chromium, about 3% cobalt, about 0.4% molybdenum, about 5% tungsten, about 5.7% aluminum, about 0.2% titanium, about 8% tantalum, about 6% rhenium, and the balance nickel.

[0055] Any of the alloy compositions described herein may contain incidental impurities.

[0056] Referring to Figure 1, a flowchart illustrating a method for forming a part is provided. The method for forming the part includes forming a channel (step 101) configured to penetrate a wall thickness of the part from an inner surface of the part to an outer surface of the part. The channel is defined by an inner channel surface. The method further includes forming an insert (step 102). The method further includes attaching the insert to the inner channel surface. The insert allows for the flow of a cooling fluid, such as air (step 103).

[0057] When the inserts 304 are attached to the inner flowpath surface 302 (see, for example, FIG. 3 ), the attached inserts provide hole redundancy to enhance film cooling effectiveness. Cooling fluid flows through the internal cooling passages for convection cooling, and then is deflected through the film cooling holes for external film cooling to the surface of the turbine component. This method according to the present disclosure can be utilized to enable effective film cooling in thin-walled sections of new or existing parts. This method according to the present disclosure can also enable reduced cooling air usage, reduced part weight, reduced low-cycle fatigue, and increased part life.

[0058] In certain embodiments, the forming step 102 may include, but is not limited to, 3D printing, metal injection molding (MIM), casting, advanced machining methods, or combinations thereof.

[0059] In certain embodiments, the attaching step 103 may include, but is not limited to, brazing, welding, mechanical fitting, or a combination thereof.

[0060] Referring to Figure 2, the coated article 200 may be a turbine component 201. The turbine component 201 may be selected from the group consisting of at least one of a hot gas path component, a combustion component, a blade (bucket), a vane (nozzle), a shroud, a combustor liner, a transition duct, a cross-fire tube collar, a venturi, a transition piece seal, and a fuel nozzle part. The turbine component 201 may include at least one plenum 205 as shown. The plenum is internally connected to cooling holes 303. Cooling fluid flows from the plenum 205 through passages defined in the airfoil of the turbine component 201 and discharges through the cooling holes 303.

[0061] Referring to FIG. 3 , a part 201 is shown including a channel 301 having a cylindrical shape and flaring upward in a top view, and an insert 304. The channel 301 is configured to penetrate a wall thickness 202 of the part 201 from an inner surface 203 of the part to an outer surface 204 of the part 201 and is defined by an inner channel surface 302 (Step 101). The insert 304 is configured to permit the flow of a cooling fluid, such as air, and has an insert outer surface 305 conforming to and attached to the inner channel surface 302 (Step 102). In certain embodiments, the insert 304 can be attached to the inner channel surface 302 by brazing, welding, or a combination thereof (Step 103). The insert 208 can include a combination of a superalloy powder and a braze matrix, where the superalloy powder has a higher melting point than the braze matrix.

[0062] Referring to FIG. 4 , a part 201 is shown including a channel 301 having a fan-shaped configuration and flaring upward in a top view, and an insert 304. The channel 301 is configured to penetrate a wall thickness 202 of the part 201 from an inner surface 203 of the part to an outer surface 204 of the part 201 and is defined by an inner channel surface 302 (Step 101). The insert 304 is configured to allow the flow of a cooling fluid, such as air, and has an insert outer surface 305 that conforms to and is attached to the inner channel surface 302 (Step 102). In certain embodiments, the insert 304 can be attached to the inner channel surface 302 by brazing, welding, or a combination thereof (Step 103). The insert 304 can include a combination of a superalloy powder and a braze matrix, where the superalloy powder has a higher melting point than the braze matrix.

[0063] Referring to FIG. 5 , a part 201 is shown including a channel 301 having a tilted-back fan-like shape and flaring upward in a top view, and an insert 304. The channel 301 is configured to penetrate the wall thickness 202 of the part 201 from the inner surface 203 of the part to the outer surface 204 of the part 201 and is defined by the inner channel surface 302 (Step 101). The insert 304 is configured to allow the flow of a cooling fluid, such as air, and has an insert outer surface 305 that conforms to and is attached to the inner channel surface 302 (Step 102). In certain embodiments, the insert 304 can be attached to the inner channel surface 302 by brazing, welding, or a combination thereof (Step 103). The insert 304 can include a combination of a superalloy powder and a braze matrix, where the superalloy powder has a higher melting point than the braze matrix.

[0064] In certain embodiments, a turbine component is provided that includes a flow passage 301 and an insert 304. The flow passage 301 is configured to penetrate the wall thickness of the component from the inner surface 203 of the component to the outer surface 204 of the component and is defined by an inner flow passage surface 302. The insert is configured to permit the flow of a cooling fluid, such as air, and has an insert outer surface 305 that conforms to and is attached to the inner flow passage surface 302. The insert has a protruding portion 306 that protrudes from the inner surface of the turbine component.

[0065] In certain embodiments, the insert 304 can protrude from the inner surface 203 of the part. In certain embodiments, the insert 304 can protrude from the outer surface 204 of the part. In other embodiments, the insert 304 can protrude from both the inner surface 203 and the outer surface 204 of the part. In some embodiments, the insert 304 can protrude from the inner and / or outer surface by 0.010 inches to 0.080 inches.

[0066] In certain embodiments, turbine components 201 may include blades (buckets), vanes (nozzles), shrouds, combustors, transition ducts, and combinations thereof.

[0067] Referring to Figure 6, a section of turbine component 201 including plenum 205 is shown in cross section along line 6-6 of Figure 2. Plenum 205 is internally fluidly connected to cooling holes 303. Inserts 304 can be installed in cooling holes 303 to provide extra hole length for improved film cooling. This is particularly effective when the casting wall thickness between plenum 205 and the hot gas path surface is insufficient. Depending on the flow path geometry, inserts 304 can have a shape selected from the group consisting of a cylindrical shape, a sector shape, an overturned sector shape, and combinations thereof.

[0068] Referring to Figure 7, a coated article 200 including a turbine component 201 is shown in cross section along line 7-7 of Figure 2. The coated article 200 includes cooling holes 303. Inserts 304 can be attached to the cooling holes 303 to provide extra hole length to enhance film cooling effectiveness. Depending on the flow path geometry, the inserts 304 can have a shape selected from the group consisting of a cylindrical shape, a sector shape, an overturned sector shape, and combinations thereof.

[0069] While the present invention has been described with reference to preferred embodiments, it will be apparent to those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from essential scope thereof. Therefore, it is intended that the present invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the present invention will include all embodiments falling within the scope of the appended claims. [Embodiment 1] A part (201) a flow channel (301) configured to penetrate a wall thickness (202) of the component (201) from an inner surface (203) of the component (201) to an outer surface (204) of the component (201), the flow channel (301) being defined by an inner flow channel surface (302); an insert (304) configured to allow the flow of a cooling fluid, the insert (304) having an insert outer surface (305) conforming to and attached to the flow channel inner surface (302); A part (201) comprising: [Embodiment 2] 2. The component (201) according to claim 1, wherein the insert (304) protrudes from the inner surface (203) of the component (201). [Embodiment 3] 2. The part (201) of claim 1, wherein the insert (304) is manufactured by a process selected from the group consisting of 3D printing, metal powder injection molding, casting, advanced machining methods, and combinations thereof. [Embodiment 4] 2. The component of claim 1, wherein the insert comprises a combination of a superalloy powder and a braze matrix, the superalloy powder having a higher melting point than the braze matrix. [Embodiment 5] 2. The component (201) of claim 1, wherein the flow path (301) has a shape selected from the group consisting of a cylindrical shape, a sector shape, an inverted sector shape, and combinations thereof. [Embodiment 6] 2. The component (201) of claim 1, wherein the insert (304) is attached to the inner flow channel surface (302) by brazing, welding, or a combination thereof. [Embodiment 7] 2. The component (201) of claim 1, wherein the component (201) comprises a material selected from the group consisting of metals, alloys, and combinations thereof. [Embodiment 8] 9. The component (201) of claim 8, wherein the component (201) comprises a hard-to-weld (HTW) alloy material selected from the group consisting of superalloys, nickel-based superalloys, cobalt-based superalloys, iron-based superalloys, titanium-based superalloys, and combinations thereof. [Embodiment 9] A turbine component (201), a flow path (301) configured to penetrate a wall thickness (202) of the turbine component (201) from an inner surface (203) of the turbine component (201) to an outer surface (204) of the turbine component (201), the flow path (301) being defined by an inner flow path surface (302); an insert (304) configured to allow the flow of a cooling fluid, the insert (304) having an insert outer surface (305) conforming to and attached to the flow channel inner surface (302); A turbine component (201), wherein the insert (304) has a protruding portion (306) that protrudes from the inner surface (203) of the turbine component (201). [Embodiment 10] 10. The turbine component (201) of embodiment 9, wherein the insert outer surface (305) is welded or brazed to the flowpath inner surface (302). [Embodiment 11] 10. The turbine component of claim 9, wherein the component comprises a material selected from the group consisting of metals, alloys, and combinations thereof. [Embodiment 12] 12. The turbine component of claim 11, wherein the turbine component comprises a hard-to-weld (HTW) alloy material selected from the group consisting of superalloys, nickel-based superalloys, cobalt-based superalloys, iron-based superalloys, titanium-based superalloys, and combinations thereof. [Embodiment 13] A method for forming a part (201), comprising: forming (101) a channel (301) defined by a channel inner surface (302) configured to penetrate a wall thickness (202) of the component (201) from an inner surface (203) of the component (201) to an outer surface (204) of the component (201); forming an insert (304) (102); Step (103) of attaching the insert (304) to the flow channel interior surface (302), the insert (304) being configured to allow the flow of a cooling fluid; A method comprising: [Embodiment 14] 14. The method of claim 13, wherein the insert (304) protrudes from the inner surface (203) of the part (201). [Embodiment 15] 14. The method of claim 13, wherein the component (201) is a turbine component (201). [Embodiment 16] 14. The method of claim 13, wherein the insert (304) is formed by a process selected from the group consisting of 3D printing, metal powder injection molding, casting, advanced machining methods, and combinations thereof. [Embodiment 17] 14. The method of claim 13, wherein the insert (304) is a combination of a superalloy powder and a braze matrix, the superalloy powder having a higher melting point than the braze matrix. [Embodiment 18] 14. The method of claim 13, wherein the attaching (103) is performed by a process selected from the group consisting of brazing, welding, mechanical fitting, and combinations thereof. [Embodiment 19] 14. The method of claim 13, wherein the channel (301) has a shape selected from the group consisting of a cylindrical shape, a sector shape, an overturned sector shape, and combinations thereof. [Embodiment 20] 14. The method of claim 13, wherein the component (201) comprises a hard-to-weld (HTW) alloy material selected from the group consisting of superalloys, nickel-based superalloys, cobalt-based superalloys, iron-based superalloys, titanium-based superalloys, and combinations thereof. [Explanation of symbols]

[0070] 200 Goods 201 parts, turbine parts 202 Wall thickness 203 Inside 204 Exterior 205 Plenum 301 Flow path 302 Inner surface of flow path 303 Cooling hole 304 Insert 305 Insert outer surface 306 Protruding part

Claims

1. A turbine component (201), comprising: a plenum (205) within the turbine component (201), the plenum (205) defining a wall thickness (202) between an inner surface (203) of the plenum (205) and an outer surface (204) of the turbine component (201), the outer surface (204) of the turbine component (201) being a hot gas path surface; a flow passage (301) configured to penetrate the wall thickness (202) between an inner surface (203) of the plenum (205) and an outer surface (204) of the turbine component (201), the flow passage (301) being defined by the flow passage inner surface (302), and the wall thickness (202) limiting the length of the flow passage (301) to prevent adequate film cooling; an insert (304) configured to allow film cooling fluid to flow from the plenum (205) to an exterior surface (204) of the turbine component (201), the insert (304) having an insert exterior surface (305) that conforms to and is attached to the flow passage interior surface (302), the insert (304) having a length greater than a length of the flow passage (301) and protruding from the inner surface (203) of the plenum (205) by 0.010 inches (0.25 mm) to 0.080 inches (2.0 mm) to provide the flow passage (301) with excess length to enhance film cooling effectiveness; A turbine component (201) comprising:

2. The turbine component (201) of any preceding claim, wherein the insert (304) comprises a combination of a superalloy powder and a braze matrix, the superalloy powder having a higher melting point than the braze matrix.

3. The turbine component (201) of claim 1 or claim 2, wherein the turbine component (201) comprises a material selected from the group consisting of metals, alloys, and combinations thereof.

4. 4. The turbine component (201) of claim 3, wherein the turbine component (201) comprises a difficult-to-weld (HTW) alloy material selected from the group consisting of superalloys, nickel-based superalloys, cobalt-based superalloys, iron-based superalloys, titanium-based superalloys, and combinations thereof.

5. The turbine component (201) of any one of claims 1 to 4, wherein the turbine component (201) is a turbine nozzle casting.

6. 1. A method for forming a turbine component (201), the turbine component (201) including a plenum (205) within the turbine component (201), a wall thickness (202) defined between an inner surface (203) of the plenum (205) and an outer surface (204) of the turbine component (201), the outer surface (204) of the turbine component (201) being a hot gas path surface, the method comprising: forming a flow passage (301) configured to penetrate the wall thickness (202) between an inner surface (203) of the plenum (205) and an outer surface (204) of the turbine component (201), the flow passage (301) being defined by the flow passage inner surface (302), and the wall thickness (202) limiting the length of the flow passage (301) to provide insufficient film cooling effectiveness; forming an insert (304) (102); attaching an insert (304) to the flowpath inner surface (302), the insert (304) configured to channel film cooling fluid from the plenum (205) to the outer surface (204) of the turbine component (201), the insert (304) having a length greater than the length of the flowpath (301) and extending 0.010 inches (0.25 mm) to 0.080 inches (2.0 mm) beyond the inner surface (203) of the plenum (205) to provide the flowpath (301) with excess length to enhance film cooling effectiveness; A method comprising:

7. The method of claim 6, wherein the insert (304) is formed by a process selected from the group consisting of 3D printing, metal powder injection molding, casting, advanced machining methods, and combinations thereof.

8. 8. The method of claim 6 or claim 7, wherein the attaching step (103) is performed by a process selected from the group consisting of brazing, welding, mechanical fitting, and combinations thereof.

9. 9. The method of any one of claims 6 to 8, wherein the insert (304) comprises a combination of a superalloy powder and a braze matrix, the superalloy powder having a higher melting point than the braze matrix, and the turbine component (201) comprises a difficult-to-weld (HTW) alloy material selected from the group consisting of superalloys, nickel-based superalloys, cobalt-based superalloys, iron-based superalloys, titanium-based superalloys, and combinations thereof.

10. The method of any one of claims 6 to 9, wherein the turbine component (201) is a turbine nozzle casting.

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