Article and method for making an article

1. A method for making shaped cooling holes in an article, comprising the steps of:

providing a metal alloy powder;

forming an initial layer with the metal alloy powder, the initial layer having a preselected thickness and a preselected shape, the preselected shape including at least one aperture;

sequentially forming an additional layer over the initial layer with the metal alloy powder, the additional layer having a second preselected thickness and a second preselected shape, the second preselected shape including at least one aperture corresponding to the at least one aperture in the initial layer;

joining the additional layer to the initial layer, forming a structure having a predetermined thickness, a predetermined shape, and at least one aperture having a predetermined profile;

providing a substrate; and

attaching the structure to the substrate.

2. The method of claim 1 , further comprising repeating the steps of sequentially forming the additional layer over a previously formed layer and joining the additional layer to the previously formed layer, each of the additional layers increasing the thickness of the structure until the predetermined thickness is obtained.

3. The method of claim 1 , further comprising the additional steps of:

masking the at least one aperture having the predetermined profile; and

applying a coating over an exposed surface of the structure attached to the substrate.

4. The method of claim 1 , comprising the additional step of forming metering holes in the substrate through the at least one aperture having a predetermined profile, the metering holes providing a passageway for fluid through the attached structure, the passageway including the at least one aperture having the predetermined profile.

5. The method of claim 1 , wherein the structure is attached to the substrate by a process selected from the group consisting of welding, brazing, and diffusion bonding.

6. The method of claim 1 , wherein the structure is attached over an outer surface of the substrate.

7. The method of claim 1 , further including a step of modifying a surface of the substrate to provide a channel corresponding to and accepting the structure.

8. The method of claim 1 , wherein the predetermined profile of the at least one aperture is an arcuate-shaped profile.

9. The method of claim 1 , wherein the predetermined profile of the at least one aperture is a conically-shaped profile.

10. The method of claim 1 , wherein the predetermined profile of the at least one aperture has an opening of at least 254 μm (0.010 inches).

11. The method of claim 1 , wherein the predetermined profile of the at least one aperture forms an angle with a surface of the structure, the angle being selected from the group consisting of up to 90°, between 10° and 50°, and about 30°, wherein 90° is an aperture that is perpendicular to the surface of the structure.

12. The method of claim 1 , wherein the initial layer and each additional layer is formed to a thickness in the range of 20-100 μm (0.0008-0.004 inches).

13. The method of claim 1 , wherein the structure is provided with a predetermined thickness in the range of 250-6350 μm (0.010-0.250 inches).

14. The method of claim 1 , wherein the substrate comprises an alloy selected from the group consisting of gamma prime superalloys and stainless steels.

15. The method of claim 1 , wherein the structure comprises an alloy selected from the group consisting of stainless steels, superalloys, and cobalt based alloys.

16. The method of claim 1 , wherein the step of forming the initial layer further comprises the steps of:

depositing the metal alloy powder forming an initial powder layer;

providing a focused energy source; and then

melting the metal alloy powder of the initial powder layer with the focused energy source, transforming the initial powder layer to the initial layer.

17. The method of claim 1 , further including the additional steps of, after forming the structure:

hot isostatically pressing the structure at an elevated temperature and elevated pressure sufficient to further consolidate the structure; and then

solutionizing the structure at an elevated temperature and for a time sufficient for distributing segregated alloying elements within the structure.

18. The method of claim 11 , wherein the predetermined profile of the at least one aperture forms an angle with a surface of the structure, the angle being selected from the group consisting of between 10° and 50°, and about 30°.