Manufacturing component using high and low melt braze

1 . A method, comprising:

arranging first braze material on a substrate, the first braze material including a first melting point;

depositing second braze material on the first braze material and sintering the second braze material to the first braze material to provide a sintered second braze material, and a second melting point of the second braze material is less than the first melting point; and

forming a braze cladding on the substrate, the forming of the braze cladding comprising melting the first braze material and the sintered second braze material to diffusion bond the first braze material and the sintered second braze material to the substrate, wherein at least some of the sintered second braze material diffuses across the first braze material into the substrate during the diffusion bonding.

2 . A method, comprising:

disposing a first braze material on a substrate, the first braze material having a first melting point;

depositing second braze powder on the first braze material and sintering the second braze powder to the first braze material to provide a sintered second braze material, the sintered second braze material having a second melting point that is less than the first melting point; and

heating the first braze material and the sintered second braze material to melt the first braze material and the sintered second braze material and diffusion bond the first braze material and the sintered second braze material to the substrate to provide a cladding on the substrate.

3 . The method of claim 2 , wherein

the first braze material comprises a metal alloy component and a braze component; and

the braze component has a lower melting point than the metal alloy component.

4 . The method of claim 3 , wherein

the first braze material has a first ratio of the metal alloy component to the braze component; and

the second braze powder comprises the metal alloy component and the braze component, and the second braze powder has a second ratio of the metal alloy component to the braze component that is less than the first ratio.

5 . The method of claim 3 , wherein the metal alloy component and the substrate comprise a common metal alloy.

6 . The method of claim 2 , wherein the substrate comprises a cobalt alloy.

7 . The method of claim 2 , wherein the substrate comprises an aluminum alloy.

8 . The method of claim 2 , wherein at least one of the first braze material or the second braze powder comprises boron.

9 . The method of claim 2 , wherein at least one of the first braze material or the second braze powder comprises silicon.

10 . The method of claim 2 , wherein

the first braze material is a sintered first braze material;

the disposing of the first braze material comprises depositing first braze powder on the substrate; and

the first braze powder is sintered to the substrate during the depositing of the first braze powder to provide the sintered first braze material.

11 . The method of claim 10 , wherein the depositing of the first braze powder comprises

directing the first braze powder towards the substrate through a nozzle; and

sintering the first braze powder using a laser beam.

12 . The method of claim 11 , wherein the depositing of the second braze powder further comprises:

directing the second braze powder towards the first braze material through a nozzle; and

sintering the second braze powder using a laser beam.

13 . The method of claim 2 , wherein at least one of the first braze material is disposed on the substrate or the second braze powder is deposited on the first braze material using an additive manufacturing device.

14 . The method of claim 2 , wherein at least one of

the first braze material is provided in a first braze tape, and the disposing of the first braze material comprises laying the first braze tape on the substrate; and

the second braze powder is provided in a second braze tape, and the disposing of the second braze powder comprises laying the second braze tape on the first braze material.

15 . The method of claim 2 , wherein the heating of the first braze material and the sintered second braze material is performed in a vacuum furnace subsequent to the depositing of the first braze material and the second braze powder.

16 . The method of claim 2 , wherein the substrate is a part of a component of an engine.

17 . A method, comprising:

providing a substrate with a first braze material and a second braze material, the first braze material arranged on the substrate, the first braze material comprising a first ratio of a metal alloy component to a braze component, the second braze material arranged on the first braze material and sintered to the first braze material to provide a sintered second braze material, the second braze material comprising a second ratio of the metal alloy component to the braze component, and the second ratio less than the first ratio; and

heating the first braze material and the sintered second braze material to melt the first braze material and the sintered second braze material and diffusion bond the first braze material and the sintered second braze material to the substrate.

18 . The method of claim 17 , wherein the second braze material has a lower melting point than the first braze material.