Cladding and freeform deposition for coolant channel closeout

1. A method of fabricating a coolant channel closeout jacket, comprising the steps of:

providing a base structure having an outer surface;

cladding said outer surface with a first material wherein a clad structure is fabricated, said clad structure having an outer clad surface;

machining coolant channels in said clad structure wherein each of said coolant channels extends through said first material and into said base structure, wherein a line of tangency relative to said outer clad surface is defined for each point on said outer clad surface;

providing a feedstock supply for depositing linear rows of a metal feedstock onto said outer clad surface of said clad structure having said coolant channels, said metal feedstock being selected from the group consisting of said first material and a second material wherein said second material is weldable to said first material;

providing an energy source for generating a beam of weld energy having a cross-sectional area;

positioning said feedstock supply to deposit said linear rows of said metal feedstock onto a portion of said outer clad surface having said coolant channels, wherein a first angle between said metal feedstock discharged from said feedstock supply and said line of tangency is maintained in a range of 20-90°; and

positioning said energy source to direct said beam of weld energy towards a portion of said linear rows deposited on said portion of said outer clad surface, wherein less than 30% of said cross-sectional area of said beam of weld energy impinges on a currently-deposited one of said linear rows, and wherein a second angle between said beam of weld energy and said line of tangency is maintained in a range of 5-65°.

2. A method according to claim 1 , further comprising the step of introducing relative rotation between said clad structure and a combination of said feedstock supply and said energy source, wherein each of said linear rows circumscribes said clad structure.

3. A method according to claim 1 , wherein each of said linear rows is perpendicular to said coolant channels.

4. A method according to claim 1 , wherein greater than 70% of said cross-sectional area of said beam of weld energy impinges on another one of said linear rows immediately adjacent to said currently-deposited one of said linear rows.

5. A method according to claim 1 , wherein said clad structure has a longitudinal axis, and wherein said method further comprises the step of positioning said clad structure wherein an angle between said longitudinal axis of said clad structure and a local force of gravity is maintained in a range of 5-70°.

6. A method according to claim 1 , further comprising the step of depositing additional linear rows of said metal feedstock on said outer clad surface where none of said coolant channels are formed.

7. A method of fabricating a coolant channel closeout jacket, comprising the steps of:

providing a base structure having an outer surface;

cladding said outer surface with a first material wherein a clad structure is fabricated, said clad structure having an outer clad surface;

machining coolant channels in said clad structure wherein each of said coolant channels extends through said first material and into said base structure, wherein a line of tangency relative to said outer clad surface is defined for each point on said outer clad surface;

directing a metal feedstock towards a portion of said outer clad surface of said clad structure where said coolant channels are formed therein, said metal feedstock being selected from the group consisting of said first material and a second material wherein said second material is weldable to said first material, said metal feedstock being directed along a first angle between said metal feedstock and said line of tangency, said first angle being maintained in a range of 20-90°, wherein said metal feedstock is deposited in a linear row on said portion of said outer clad surface;

generating a beam of weld energy having a cross-sectional area; and

directing said beam of weld energy towards said linear row wherein less than 30% of said cross-sectional area of said beam of weld energy impinges on said linear row, and wherein a second angle between said beam of weld energy and said line of tangency is maintained in a range of 5-65°.

8. A method according to claim 7 , further comprising the step of rotating said clad structure about a longitudinal axis thereof during said steps of directing, wherein said linear row circumscribes said clad structure.

9. A method according to claim 7 , wherein said linear row is perpendicular to said coolant channels.

10. A method according to claim 7 , wherein another linear row of said metal feedstock lies immediately adjacent to said linear row, and wherein greater than 70% of said cross-sectional area of said beam of weld energy impinges on said another linear row.

11. A method according to claim 7 , wherein said clad structure has a longitudinal axis, and wherein said method further comprises the step of positioning said clad structure wherein an angle between said longitudinal axis of said clad structure and a local force of gravity is maintained in a range of 5-70°.

12. A method according to claim 7 , further comprising the step of depositing additional linear rows of said metal feedstock on said outer clad surface where none of said coolant channels are formed.

13. A method of fabricating a coolant channel closeout jacket, comprising the steps of:

providing a base structure having an outer surface;

cladding said outer surface with a first material wherein a clad structure is fabricated, said clad structure having an outer clad surface;

machining coolant channels in said clad structure wherein each of said coolant channels extends through said first material and into said base structure, wherein a line of tangency relative to said outer clad surface is defined for each point on said outer clad surface;

directing a metal feedstock towards a portion of said outer clad surface of said clad structure where said coolant channels are formed therein, said metal feedstock being selected from the group consisting of said first material and a second material wherein said second material is weldable to said first material, said metal feedstock being directed along a first angle between said metal feedstock and said line of tangency, said first angle being maintained in a range of 20-90°, wherein said metal feedstock is deposited in a linear row on said portion of said outer clad surface;

generating a beam of weld energy having a cross-sectional area;

directing said beam of weld energy towards said linear row wherein less than 30% of said cross-sectional area of said beam of weld energy impinges on said linear row, and wherein a second angle between said beam of weld energy and said line of tangency is maintained in a range of 5-65°; and

repeating said steps of directing until said coolant channels are covered by a plurality of said linear row.

14. A method according to claim 13 , further comprising the step of rotating said clad structure about a longitudinal axis thereof during said steps of directing, wherein each said linear row circumscribes said clad structure.

15. A method according to claim 13 , wherein each said linear row is perpendicular to said coolant channels.

16. A method according to claim 13 , wherein another linear row of said metal feedstock lies immediately adjacent to said linear row, and wherein greater than 70% of said cross-sectional area of said beam of weld energy impinges on said another linear row.

17. A method according to claim 13 , wherein said clad structure has a longitudinal axis, and wherein said method further comprises the step of positioning said clad structure wherein an angle between said longitudinal axis of said clad structure and a local force of gravity is maintained in a range of 5-70°.

18. A method according to claim 13 , further comprising the step of depositing additional linear rows of said metal feedstock on said outer clad surface where none of said coolant channels are formed.