Method of selectively bonding braze powders to a surface

1. A method of diffusion bonding comprising:

applying a braze powder comprising a braze alloy to a first surface;

directing a laser beam onto the braze powder while the laser beam moves along a predetermined path relative to the first surface, the laser beam selectively heating the braze powder along the predetermined path to sinter and bond the braze powder to the first surface, the braze powder being heated to a sintering temperature that is below a solidus of the braze alloy, thereby forming a braze deposit at one or more predetermined locations on the first surface; and

after forming the braze deposit, removing excess braze powder not selectively heated by the laser from the first surface,

after forming the braze deposit, assembling a first component comprising the first surface with a second component comprising a mating surface to form an assembly, the braze deposit on the first surface contacting the mating surface; and

exposing the assembly to a bonding temperature and a compressive force, thereby diffusion bonding the first component to the second component to form a monolithic third component comprising a bonded interface.

2. The method of claim 1 , wherein applying the braze powder to the first surface comprises spraying, scattering, or dusting the braze powder over the surface.

3. The method of claim 1 , wherein the braze powder is applied to the first surface in an amount sufficient to achieve a mass density in a range from about 0.04 g/in 2 to about 0.25 g/in 2 .

4. The method of claim 1 , wherein the predetermined path is a continuous path.

5. The method of claim 1 , wherein the predetermined path is a discontinuous path, the laser beam being operated intermittently while moving.

6. The method of claim 1 , wherein the first surface is a discontinuous surface comprising surface regions separated by gaps, and wherein the braze deposit is formed on the surface regions.

7. The method of claim 1 , wherein the laser beam is generated by a laser selected from the group consisting of: gas laser, solid state laser, and fiber laser.

8. The method of claim 1 , wherein the laser beam is a pulsed laser beam.

9. The method of claim 1 , wherein the laser beam is a continuous laser beam.

10. The method of claim 1 , wherein the laser beam is operated at a power level and a scan rate sufficient to sinter the braze powder without inducing melting.

11. The method of claim 1 , wherein the braze powder along the predetermined path is selectively heated to a sintering temperature in a range from about 400° C. to about 800° C.

12. The method of claim 1 , wherein removing the excess braze powder from the surface comprises vibrating, overturning, washing, brushing, or spraying the first surface.

13. The method of claim 1 , wherein the first surface of the first component comprises a metal alloy.

14. The method of claim 1 , wherein the first component comprises part of an airfoil, a combustion liner, or a heat shield of a gas turbine engine.

15. The method of claim 1 , wherein the braze powder comprises a nickel-based braze alloy, a titanium-based braze alloy, or an iron-based braze alloy.

16. The method of claim 1 , wherein the first component and the second component comprise a single-crystalline structure.

17. The method of claim 1 , wherein the first component and second component comprise a nickel-base alloy.

18. The method of claim 1 , wherein the first component comprises a coversheet and the second component comprises a spar, the monolithic third component comprising an airfoil for use in a gas turbine engine.

19. The method of claim 1 , wherein the bonding temperature is in a range from about 900° C. to about 1275° C.