Erosion-shielded turbine blades and methods of manufacturing the same

A method of reconditioning an erosion-shielded turbine blade, the method comprising:

• providing a turbine blade for use with a rotary machine, the turbine blade including an airfoil extending between a root and a tip, the airfoil including a pressure side and an opposite suction side, each of the pressure and suction sides extending between a leading edge and a trailing edge, and a damaged region along the leading edge;
• removing the damaged region from the leading edge to:
• form a recessed area in the leading edge proximate the tip, the recessed area having radial length that is shorter than a radial length of the airfoil, and
• define a remaining portion of the leading edge positioned radially adjacent the recessed area;
• printing a green body part by an additive manufacturing process by selectively depositing a binder solution across a particulate erosion-resistant material;
• sintering the green body part to produce a post-sintering erosion shield that includes densified erosion-resistant material, wherein sintering the green body part is performed at a suitable temperature and for a suitable time duration to facilitate producing the post-sintering erosion shield including the densified erosion-resistant material with an equiaxed grain structure and a relative density greater than or equal to about 92%;
• and
• coupling the post-sintering erosion shield within the recessed area formed in the leading edge of the turbine blade after removing the damaged region, the post-sintering erosion shield including an outer surface that is flush with the defined, remaining portion of the leading edge for the airfoil formed radially adjacent the recessed area,
• wherein the post-sintering erosion shield forms a continuous and smooth transition for the airfoil between the outer surface and the remaining portion of the leading edge.

A method of manufacturing an erosion-shielded turbine blade, the method comprising:

• providing a turbine blade for use with a rotary machine, the turbine blade including an airfoil extending between a root and a tip, the airfoil including:
• a pressure side and an opposite suction side, each of the pressure and suction sides extending between a leading edge and a trailing edge,
• a recessed area formed in the leading edge proximate the tip, the recessed area having a radial length that is shorter than a radial length of the airfoil, and
• a tip shroud fixedly coupled to the tip;
• printing a green body part by an additive manufacturing process by selectively depositing a binder solution across a particulate erosion-resistant material;
• sintering the green body part to produce a post-sintering erosion shield that includes densified erosion-resistant material, wherein sintering the green body part is performed at a suitable temperature and for a suitable time duration to facilitate producing the post-sintering erosion shield including the densified erosion-resistant material with an equiaxed grain structure and a relative density greater than or equal to about 92%;
• and
• coupling the erosion shield within the recessed area formed in the leading edge of the turbine blade and to an end of the tip shroud proximate to the leading edge such that the erosion shield extends substantially across the end of the tip shroud,
• wherein the erosion shield includes an outer surface that is flush with a remaining portion of the leading edge for the airfoil formed adjacent the recessed area, and the erosion shield forms a continuous and smooth transition for the airfoil between the outer surface and the remaining portion of the leading edge.