# US 8,739,404 B2 · Turbine components with cooling features and methods of manufacturing the same

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- Number: US 8,739,404 B2
- Document ID: US8739404B2
- Status: Granted
- Kind: B2
- Application number: 12/953,177
- Filed: 2010-11-23
- Published: 2012-05-24
- Granted: 2014-06-03
- Earliest claimed: 2010-11-23
- Assignees: General Electric Company
- Applicants: Ronald Scott Bunker; Bin Wei; Ann Melinda Ritter; Don Mark Lipkin; Raul Basilio Rebak; Lawrence Bernard Kool; Dennis Michael Gray
- Inventors: Ronald Scott Bunker; Bin Wei; Ann Melinda Ritter; Don Mark Lipkin; Raul Basilio Rebak; Lawrence Bernard Kool; Dennis Michael Gray
- Web page: https://patentgrep.com/patent/US8739404B2

## CPC

- F01D 5/147: {Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18)}
- F05D 2230/21: by casting
- F05D 2230/40: Heat treatment
- F05D 2230/90: Coating; Surface treatment
- F05D 2260/202: by film cooling
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- Y10T 29/49229: Prime mover or fluid pump making
- Y10T 29/4932: Turbomachine making
- Y10T 29/49339: Hollow blade
- Y10T 29/49341: with cooling passage
- F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D)
- F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The present disclosure is directed to the use and manufacture of cooling features within a component used in a hot gas path, such as within a turbine. In one embodiment, channels are formed within an external surface of the component and filled with a removable material. The external surface and channels may then be coated with one or more layers, such as a structural layer and/or top coat. The removable material may then be removed to leave the channels free of the removable material.

## Claims

### Claim 1

A method for manufacturing a turbine component, comprising:
forming one or more channels in an external surface of the turbine component;
forming one or more holes between the one or more channels and an interior region of the turbine component;
mechanically pressing a single filler material into the one or more channels so as to deform the single filler material to conform to and substantially fill the one or more channels, wherein the single filler material comprises a metal or a metal alloy wire that conforms to a cross-sectional shape of the respective channels;
applying one or more coatings to the external surface of the turbine component over the one or more channels filled with the metal or metal alloy wire;
forming one or more holes through the coatings; and
removing the metal or metal alloy wire from the channels.

### Claim 2 (depends on 1)

The method of claim 1 wherein the one or more coatings comprise a nickel or cobalt alloy.

### Claim 3 (depends on 1)

The method of claim 1 comprising heat treating the turbine component after removing the metal or metal alloy from the channels.

### Claim 4 (depends on 1)

The method of claim 1 wherein applying at least one coating comprises depositing the coating on the external surface of the turbine component using one or more of high velocity oxy-fuel deposition, ion plasma deposition, low pressure plasma spray, high velocity air-fuel deposition, or cold spray.

### Claim 5 (depends on 1)

The method of claim 1 wherein the one or more channels are formed using one or more of abrasive liquid jet, milling electrodischarge machining, laser machining, or plunge electro-chemical machining.

### Claim 6 (depends on 1)

The method of claim 1 wherein the metal or metal alloy wire comprises one or more of Cu, Mo, Ni, W, Al, monel, or nichrome.

### Claim 7 (depends on 1)

The method of claim 1 wherein removing the metal or metal alloy wire comprises leaching, dissolving, etching, oxidizing, or melting, the metal or metal alloy wire.

### Claim 8 (depends on 1)

The method of claim 1 comprising applying a topcoat over the coating and forming the one or more holes through the topcoat as well as the coating.

### Claim 9 (depends on 8)

The method of claim 8 wherein the topcoat comprises a ceramic material.

### Claim 10 (depends on 1)

The method of claim 1 wherein removing the metal or metal alloy wire from the channels comprises flushing with acid to remove the metal or metal alloy wire.

### Claim 11 (depends on 1)

The method of claim 1 wherein at least one of forming the one or more channels, forming the one or more holes to the interior region, forming the one or more holes through the coating, or filling the one or more channels are performed in accordance with a programmed process controlling a robotic interface.

### Claim 12 (depends on 1)

The method of claim 1 comprising applying an oxidation-resistant coating to one or both of the channel surfaces or the external surface of the turbine component after removal of the metal or metal alloy from the channels.

### Claim 13 (depends on 12)

The method of claim 12 wherein the oxidation-resistant coating comprises an aluminide coating applied by one or more of vapor-phase aluminizing, pack aluminizing, or CVD aluminizing.

### Claim 14 (depends on 12)

The method of claim 12 wherein the oxidation-resistant coating comprises a material selected from the alloy families (Ni,Co)CrAlY, NiAl, Ni3Al, and Ni—Ni3Al.

### Claim 15 (depends on 12)

The method of claim 12 wherein the oxidation-resistant coating acts as a thermal barrier bond coating.

### Claim 16

A method for forming a hot gas path component, comprising:
forming one or more channels in an external surface of the hot gas path component;
connecting the one or more channels to one or more internal passages within the hot gas path component such that channels and the internal passages are in fluid communication;
mechanically pressing a single filler material into the one or more channels to deform the single filler material to conform to the one or more channels such that the one or more channels are substantially filled with the single filler material, wherein the single filler material comprises a solid metal or a metal alloy material that conforms to a cross-sectional shape of the respective channels;
applying at least a first layer to the external surface of the hot gas path component such that the one or more channels are covered;
forming one or more cooling holes through at least the first layer; and removing the solid metal or metal alloy material from the channels.

### Claim 17 (depends on 16)

The method of claim 16, wherein the one or more channels are formed using an automated or robotic machining process.

### Claim 18 (depends on 16)

The method of claim 16 wherein the one or more channels are formed using one or more of milling electro-discharge machining, plunge electro-chemical machining, laser machining, or abrasive liquid jets.

### Claim 19 (depends on 16)

The method of claim 16 wherein the metal or metal alloy material comprises a metal or metal alloy wire that conforms to and substantially fills the one or more channels when mechanically pressed into the channels.

### Claim 20 (depends on 16)

The method of claim 16, wherein the metal or metal alloy material comprises one or more of Cu, Al, W, Mo, Ni, monel, or nichrome.

### Claim 21 (depends on 16)

The method of claim 16 wherein applying the first layer comprises applying a layer of a substantially nickel or cobalt alloy using one or more of high-velocity oxy-fuel deposition, ion plasma deposition, low pressure plasma spray, high velocity air-fuel deposition, or cold spray.

### Claim 22 (depends on 16)

The method of claim 16 wherein removing the solid metal or metal alloy material from the channels comprises flushing with acid to remove the solid metal or metal alloy material.