METHOD OF MAKING A COMBUSTION TURBINE COMPONENT USING THERMALLY SPRAYED TRANSIENT LIQUID PHASE FORMING LAYER
A method of making a combustion turbine component includes thermal spraying a transient liquid phase (TLP) forming layer onto a combustion turbine component substrate and thermal spraying a main material layer onto the TLP forming layer. The combustion turbine component substrate, TLP forming layer, and main material layer are heat treated to thereby bond the main material layer to the combustion turbine component substrate.
1 . A method of making a combustion turbine component comprising:
thermally spraying a transient liquid phase (TLP) forming layer onto a combustion turbine component substrate;
thermally spraying a main material layer onto the TLP forming layer; and
heat treating the combustion turbine component substrate, TLP forming layer, and main material layer to thereby bond the main material layer to the combustion turbine component substrate.
2 . The method of claim 1 wherein the TLP forming layer comprises a melting point depressor.
3 . The method of claim 2 wherein the melting point depressor comprises at least one of boron, silicon, tantalum, and manganese.
4 . The method of claim 1 wherein the TLP forming layer comprises MCrAlY, with M being selected from the group comprising Fe, Co, Ni, and mixtures thereof.
5 . The method of claim 1 wherein thermally spraying the TLP forming layer comprises thermally spraying a feedstock metallic powder comprising a TLP forming alloy.
6 . The method of claim 1 wherein thermally spraying the main material layer onto the TLP forming layer comprises thermally spraying a feedstock metallic powder comprising a superalloy onto the TLP forming layer.
7 . The method of claim 1 wherein the main material layer comprises an aluminium based superalloy.
8 . The method of claim 1 further comprising forming a bond layer on the main material layer.
9 . The method of claim 1 further comprising forming a thermal barrier layer on the main material layer.
10 . A method of making a combustion turbine component comprising:
providing a combustion turbine component substrate having cooling passageways thereon, the cooling passageways being filled with a masking material;
thermally spraying a transient liquid phase (TLP) forming layer onto the combustion turbine component substrate;
thermally spraying a main material layer onto the TLP forming layer;
removing the masking material from the cooling passageways.
heat treating the combustion turbine component substrate, TLP forming layer, and main material layer to thereby bond the main material layer to the combustion turbine component substrate; and
11 . The method of claim 10 wherein the TLP forming layer comprises a melting point depressor.
12 . The method of claim 11 wherein the melting point depressor comprises at least one of boron, silicon, tantalum, and manganese.
13 . The method of claim 10 wherein the TLP forming layer further comprises MCrAlY, with M being selected from the group comprising Fe, Co, Ni, and mixtures thereof.
14 . The method of claim 10 wherein the main material layer comprises aluminium based superalloy.
15 . A method of making a combustion turbine component comprising:
thermally spraying a transient liquid phase (TLP) forming layer comprising a melting point depressor onto a combustion turbine component substrate;
thermally spraying a main material layer comprising an aluminum based superalloy onto the TLP forming layer, with M being selected from the group comprising Fe, Co, Ni, and mixtures thereof; and
heat treating the combustion turbine component substrate, TLP forming layer, and main material layer to thereby bond the main material layer to the combustion turbine component substrate.
16 . The method of claim 15 wherein the melting point depressor comprises at least one of boron, silicon, tantalum, and manganese.
17 . The method of claim 16 wherein the TLP forming layer further comprises MCrAlY, with M being selected from the group comprising Fe, Co, Ni, and mixtures thereof.
18 . The method of claim 15 further comprising forming a bond layer on the main material layer.
19 . The method of claim 15 further comprising forming a thermal barrier layer on the main material layer.
20 . The method of claim 15 wherein thermally spraying the TLP forming layer comprises thermally spraying a feedstock metallic powder comprising a TLP forming alloy; and wherein thermally spraying the main material layer onto the TLP forming layer comprises thermally spraying a feedstock metallic powder comprising a superalloy onto the TLP forming layer.