# US 10,369,630 B2 · Polyhedral-sealed article and method for forming polyhedral-sealed article

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- Number: US 10,369,630 B2
- Document ID: US10369630B2
- Status: Granted
- Kind: B2
- Application number: 15/442,184
- Filed: 2017-02-24
- Published: 2018-08-30
- Granted: 2019-08-06
- Earliest claimed: 2017-02-24
- Assignees: General Electric Company
- Applicants: General Electric Company
- Inventors: Srikanth Chandrudu Kottilingam; Brian Lee Tollison; Yan Cui; Surinder Singh Pabla
- Web page: https://patentgrep.com/patent/US10369630B2

## CPC

- B22F 7/08: with one or more parts not made from powder {(B22F7/062 takes precedence)}
- B22F 10/14: by jetting of binder onto a bed of metal powder
- B29C 64/165: using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- F01D 11/127: {with a deformable or crushable structure, e.g. honeycomb}
- B22F 2998/10: Processes characterised by the sequence of their steps
- B29K 2105/16: Fillers
- B29K 2505/00: Use of metals, their alloys or their compounds, as filler
- B29L 2031/7504: {Turbines}
- F05D 2240/55: Seals
- F05D 2250/132: hexagonal
- F05D 2250/283: honeycomb
- F05D 2250/38: angled, e.g. sweep angle
- F05D 2300/171: Steel alloys
- F05D 2300/174: Titanium alloys, e.g. TiAl
- F05D 2300/175: Superalloys
- Y02P 10/25: Process efficiency
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A polyhedral-sealed article is disclosed including an article having a surface and a polyhedral seal layer disposed on the surface. The polyhedral seal layer includes a polyhedral structure having a plurality of polyhedral units. The polyhedral seal layer further includes at least one of a composition including an HTW composition, a heterogeneous pattern of the polyhedral structure, an orientation of the polyhedral structure extending from the surface at non-orthogonal angle, and at least one polyhedral unit conformation other than a hexagonal prism. A method for forming the polyhedral-sealed article is disclosed including forming a polyhedral seal layer by binder jet additive manufacturing and disposing the polyhedral seal layer on a surface of an article.

## Claims

### Claim 1

A polyhedral-sealed article, comprising: an article having a surface; and a polyhedral seal layer disposed on the surface, the polyhedral seal layer including: a polyhedral structure having a plurality of polyhedral units; and a composition including a hard-to-weld (HTW) composition, wherein the HTW composition includes a pre-sintered preform (PSP) material including a first alloy and a second alloy intermixed with one another as distinct phases.

### Claim 2 (depends on 1)

The polyhedral-sealed article of claim 1, further including a heterogeneous pattern of the polyhedral structure, an orientation of the polyhedral structure extending from the surface at a non-orthogonal angle, and at least one polyhedral unit conformation other than a hexagonal prism.

### Claim 3 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the plurality of polyhedral units include the polyhedral unit conformation selected from the group consisting of polyhedra having between four and thirty-two faces, polyhedra having between four and thirty-two faces with at least one face being an open face, prisms having between five and twelve faces, prisms having between five and twelve faces with at least one face being an open face, prisms having between five and twelve faces with at least one face being an open base face, and combinations thereof.

### Claim 4 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the polyhedral unit conformation varies across the polyhedral seal layer.

### Claim 5 (depends on 1)

The polyhedral-sealed article of claim 1, wherein at least one face of the plurality of the polyhedral units is a closed face formed by the surface.

### Claim 6 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the plurality of polyhedral units include hexagonal prisms with the at least one open base face, forming a honeycomb structure.

### Claim 7 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the plurality of polyhedral units includes polyhedral unit dimensions which vary across the polyhedral seal layer.

### Claim 8 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the plurality of polyhedral units includes a polyhedral unit wall thickness which varies across the polyhedral seal layer.

### Claim 9 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the polyhedral seal layer includes a composition which varies across the polyhedral seal layer.

### Claim 10 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the article is selected from the group consisting of a gas turbine article, a turbo-charger article, and a steam turbine article.

### Claim 11 (depends on 10)

The polyhedral-sealed article of claim 10, wherein the article is a gas turbine article selected from the group consisting of a hot gas path article, a nozzle in contact with angel wings, a shroud, a bucket, and a rotating part.

### Claim 12 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the polyhedral structure includes a binder jet additive manufacturing deposited structure, the binder jet additive manufacturing deposited structure including a predetermined porosity between about 5% to about 45%.

### Claim 13 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the HTW composition includes an HTW alloy selected from the group consisting of a refractory alloy, a superalloy, a nickel-based superalloy, a cobalt-based superalloy, an iron-based superalloy, an aluminum-titanium superalloy, CMSX-4, CMSX10, DS Siemet, GTD 111, GTD 222, GTD 262, GTD 444, INCONEL 100, INCONEL 700, INCONEL 738, INCONEL 792, INCONEL 939, Mar-M-200, Mar-M-247, MGA1400, MGA2400, PWA 1480, PWA 1483, PWA 1484, René N2, René N4, René N5, René N6, René 65, René 77, René 80, René 88DT, René 104, René 108, René 125, René 142, René 195, René N500, René N515, TMS-75, TMS-82, UDIMET 500, and combinations thereof.

### Claim 14 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the HTW composition includes an MCrAlY.

### Claim 15 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the first alloy includes a first melting point of at least 2,400° F. and the second alloy includes a second melting point below 2,350° F.

### Claim 16 (depends on 1)

The polyhedral-sealed article of claim 1, wherein the first alloy is selected from the group consisting of an HTW alloy, a refractory alloy, a superalloy, a nickel-based superalloy, a cobalt-based superalloy, an iron-based superalloy, a titanium-aluminum superalloy, an iron-based alloy, a steel alloy, a stainless steel alloy, a cobalt-based alloy, a nickel-based alloy, a titanium-based alloy, GTD 111, GTD 444, HAYNES 188, HAYNES 230, INCONEL 738, L605, MAR-M-247, MAR-M-509, René 108, René 142, René 195, René N2, and combinations thereof, and the second alloy is selected from the group consisting of a braze alloy, an iron-based alloy, a steel alloy, a stainless steel alloy, a cobalt-based alloy, a nickel-based alloy, a titanium-based alloy, DF-4B, D15, MAR-M-509B, BNi-2, BNi-3, BNi-5, BNi-6, BNi-7, BNi-9, BNi-10, and combinations thereof.

### Claim 17

A method for forming a polyhedral-sealed article, comprising:
forming a polyhedral seal layer by binder jet additive manufacturing, the polyhedral seal layer including a polyhedral structure having a plurality of polyhedral units and a composition including a hard-to-weld (HTW) composition; and
disposing the polyhedral seal layer on a surface of an article,
wherein the HTW composition includes a pre-sintered preform (PSP) material including a first alloy and a second alloy intermixed with one another as distinct phases.

### Claim 18 (depends on 17)

The method of claim 17, further including, either forming the polyhedral seal layer directly on the surface or following forming the polyhedral seal layer, de-binding and sintering the polyhedral seal layer, and then disposing the polyhedral seal layer on the surface and joining the polyhedral seal layer to the surface.

### Claim 19 (depends on 17)

The method of claim 17, wherein forming the polyhedral seal layer includes forming the polyhedral structure having a plurality of polyhedral units, and at least one of:
a heterogeneous pattern of the polyhedral structure;
an orientation of the polyhedral structure extending from the surface at a non-orthogonal angle; and
at least one polyhedral unit conformation other than a hexagonal prism.