Hybrid bonded configuration for blade outer air seal (BOAS)
A method of assembling a part is provided and includes forming a first section of the part, defining, in the first section, passages with dimensions as small as 0.005 inches (0.127 mm), forming a second section of the part, metallurgically bonding the first and second sections whereby the passages are delimited by the first and second sections and executing the metallurgically bonding without modifying a condition of the passages.
1 . A method of assembling a part, the method comprising:
building up a multi-layered first section of the part;
defining passages in the multi-layered first section;
building up a multi-layered second section of the part;
metallurgically bonding each layer of the multi-layered first and second sections to neighboring layers whereby the passages are delimited by respective layers of the multi-layered first and second sections; and
executing the metallurgically bonding without modifying a condition of the passages,
wherein the passages are fluidly coupled to a cooling circuit, the method further comprises defining additional passages that mirror the passages of the multi-layered first section in the multi-layered second section and the metallurgically bonding of the multi-layered first and second sections comprises metallurgically bonding the multi-layered first and second sections by FAST along a line centered between the passages and the additional passages.
2 . The method according to claim 1 , wherein the passages are as small as 0.005 inches (0.127 mm).
3 . The method according to claim 1 , wherein the part comprises a blade outer air seal (BOAS) of a gas turbine engine and the passages are fluidly coupled to a cooling circuit.
4 . The method according to claim 1 , wherein the multi-layered first and second sections comprise similar or dissimilar materials.
5 . The method according to claim 1 , further comprising coating the passages.
6 . The method according to claim 1 , wherein the building up of the multi-layered first and second sections comprise at least one of field assisted sintering technology (FAST) and/or spark plasma sintering (SPS).
7 . A method of assembling a part, the method comprising:
building up a multi-layered first curved section of the part;
defining passages in the multi-layered first curved section;
building up a multi-layered second curved section of the part;
metallurgically bonding each layer of the multi-layered first curved and second curved sections to neighboring layers whereby the passages are delimited by respective layers of the multi-layered first curved and second curved sections; and
executing the metallurgically bonding without modifying a condition of the passages,
wherein the metallurgically bonding comprises field assisted sintering technology (FAST) utilizing high amperage pulsed direct current (DC) to heat the multi-layered first curved and second curved sections for bonding through Joule heating while under uniaxial compression that accommodates respective curvatures of the multi-layered first curved and second curved sections,
wherein the passages are fluidly coupled to a cooling circuit, the method further comprises defining additional passages that mirror the passages of the multi-layered first curved section in the multi-layered second curved section and the metallurgically bonding of the multi-layered first curved and second curved sections comprises metallurgically bonding the multi-layered first curved and second curved sections by FAST along a line centered between the passages of the multi-layered first curved section and the additional passages.
8 . The method according to claim 7 , wherein the passages of the multi-layered first curved section are as small as 0.005 inches (0.127 mm).
9 . The method according to claim 7 , wherein the part comprises a blade outer air seal (BOAS) of a gas turbine engine and the passages are fluidly coupled to a cooling circuit.
10 . The method according to claim 7 , wherein the multi-layered first curved and second curved sections comprise similar or dissimilar materials.
11 . The method according to claim 7 , further comprising coating the passages of the multi-layered first curved section.
12 . The method according to claim 7 , wherein the building up of the multi-layered first curved and second curved sections comprise at least one of field assisted sintering technology (FAST) and/or spark plasma sintering (SPS).
13 . A method of assembling a blade outer seal (BOAS) of a gas turbine engine to form a curved outer air passage with a distal tip of a turbine blade, the method comprising:
building up a multi-layered first curved section of the BOAS;
defining passages in the multi-layered first curved section;
building up a multi-layered second curved section of the BOAS;
metallurgically bonding each layer of the multi-layered first curved and second curved sections to neighboring layers whereby the passages are delimited by respective layers of the multi-layered first curved and second curved sections; and
executing the metallurgically bonding without modifying a condition of the passages,
wherein the metallurgically bonding comprises field assisted sintering technology (FAST) utilizing high amperage pulsed direct current (DC) to heat the multi-layered first curved and second curved sections for bonding through Joule heating while under uniaxial compression that accommodates respective curvatures of the multi-layered first curved and second curved sections,
wherein the passages are fluidly coupled to a cooling circuit of the BOAS, the method further comprises defining additional passages that mirror the passages of the multi-layered first curved section in the multi-layered second curved section, and the metallurgically bonding of the multi-layered first curved and second curved sections comprises metallurgically bonding the multi-layered first curved and second curved sections by FAST along a line centered between the passages of the multi-layered first curved section and the additional passages.
14 . The method according to claim 13 , wherein the passages of the multi-layered first curved section are as small as 0.005 inches (0.127 mm).
15 . The method according to claim 13 , wherein the multi-layered first curved and second curved sections comprise similar or dissimilar materials.
16 . The method according to claim 13 , further comprising coating the passages of the multi-layered first curved section.
17 . The method according to claim 13 , wherein the building up of the multi-layered first curved and second curved sections comprise at least one of field assisted sintering technology (FAST) and/or spark plasma sintering (SPS).