Airfoil and method of fabricating same

A method of fabricating an airfoil, the airfoil including a tip portion including a tip portion including a first end and a second end and a body portion including a first end and a second end, said method comprising:

• forming the tip portion;
• imaging a second end of the body portion to obtain image data of one or more mortises formed therein an end portion;
• manufacturing one or more tenons extending therefrom the first end of the tip portion using the image data of the second end of the body portion, wherein the step of manufacturing includes additive manufacturing;
• depositing a bonding material on at least one of a first end of the tip portion, the one or more tenons and a second end of the body portion;
• positioning the first end of the tip portion relative to the second end of the body portion to allow sliding engagement of each of the one or more tenons into a respective one of the one or more mortise and define a mechanical interlocking interface;
• and
• coupling the first end of the tip portion to the second end of the body portion such that the tip portion and the body portion form the airfoil.

An airfoil of a rotary machine comprising:

• a tip portion comprising a first end and a second end, the tip portion including one or more additively manufactured tenons extending from the first end;
• and
• a body portion comprising a first end and a second end, said second end of the body portion configured to couple to said first end of said tip portion, said body portion including one or more mortises extending into the second end, wherein each of said one or more tenons of the tip portion are in sliding engagement with a corresponding one of said one or more mortises of the body portion,
• wherein said one or more tenons of the tip portion are based on image data of the second end of the body portion.