An air cooled integrally bladed rotor with single crystals turbine rotor blades having cooling air passages formed into an equiax rotor disk, where a mold having expendable Molybdenum tooling and reusable molybdenum tooling is used to form the IBR. An annular blade ring with openings is used to secure the single crystal rotor blades within the mold, and a number of tube tools are inserted into a bottom end of each blade that forms a cooling air supply passage within the rotor disk. Two molybdenum circular shaped hubs are used to secure a bottom end of the tube tools with the mold. The mold is filled with metal powder and high pressure is used to solidify the powder to form the IBR. Expendable tooling is removed using sublimation when exposed to oxygen. Reusable tooling is reused to form additional IBRs.

A method of manufacturing a part, the method involving providing an apparatus, the apparatus having a metal skin component; a metal HIP can and a hollow space between a portion of the HIP can and a portion of the skin component, the method further involving filling the HIP can with a metal powder; evacuating the HIP can; sealing the evacuated HIP can; and applying a HIP process to the apparatus in a HIP chamber so as to form the part.

A method for manufacturing impellers is described. The method provides for manufacturing a plurality of tubular components, each tubular component forming an inner passage, which is shaped as one of the flow passages of the final impeller. The tubular components are assembled together forming a semi-finished impeller. The semi-finished impeller is provided with annular cavities extending around the rotation axis of the impeller and gaps between adjacent tubular components. The gaps and cavities are filled with metal powder and the semi-finished impeller is subject to hot isostatic pressing, to densify the metal powder and form a monolithic final impeller.

Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (T.sub.DISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (T.sub.BLADE_MAX) is established such that T.sub.BLADE_MAX is less than T.sub.DIsK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than T.sub.DISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below T.sub.BLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

Methods for processing bonded dual alloy rotors are provided. In one embodiment, the method includes obtaining a bonded dual alloy rotor including rotor blades bonded to a hub disk. The rotor blades and hub disk are composed of different alloys. A minimum processing temperature (T.sub.DISK_PROCESS_MIN) for the hub disk and a maximum critical temperature for the rotor blades (T.sub.BLADE_MAX) is established such that T.sub.BLADE_MAX is less than T.sub.DISK_PROCESS_MIN. A differential heat treatment process is then performed during which the hub disk is heated to processing temperatures equal to or greater than T.sub.DISK_PROCESS_MIN, while at least a volumetric majority of each of the rotor blades is maintained at temperatures below T.sub.BLADE_MAX. Such a targeted differential heat treatment process enables desired metallurgical properties (e.g., precipitate hardening) to be created within the hub disk, while preserving the high temperature properties of the rotor blades and any blade coating present thereon.

A method of welding a superalloy component includes the following sequential steps. A welding step for welding a cavity using a filler metal in an inert atmosphere, where the cavity is located in the component. A covering step for covering the filler metal and a portion of the component with a weld filler layer in the inert atmosphere. The weld filler layer has a greater ductility than material comprising the component and/or material comprising the filler metal. A second covering step for covering the weld filler layer with a braze material, and subsequently performing a brazing operation. A heat treating step heat treats the component.

A method for producing a thin-walled metal part with complex geometry includes mixing a metal powder with a polymer binder in order to obtain a composite mixture, producing a flexible composite sheet from the composite mixture, cutting, in the flexible composite sheet, a preform based on a contour of the metal part, applying the preform in a mold having a surface configured with a relief of the metal part, and debinding and sintering the preform in order to obtain the metal part.

The present disclosure relates to building very large gas turbines without changing rotor materials. The gas turbine part can include a structure composed of a metal and a ternary ceramic called MAX phase, having a formula Mn+1AXn, where n=1, 2, or 3, M is an early transition metal such as Ti, V, Cr, Zr, Nb, Mo, Hf, Sc, Ta, and A is an A-group element such as Al, Si, P, S, Ga, Ge, As, Cd, In, Sn, Tl, Pb, and X is C and/or N.

A field of rotary blades, and more particularly to a method of fabricating a leading edge shield for protecting such a blade. The method includes at least steps of performing initial plastic deformation on at least one sheet from a pressure side sheet and a suction side sheet, using additive fabrication to add a reinforcement with a fiber insert on at least one of the pressure and suction side sheets, closing the pressure and suction side sheets around a core after the initial plastic deformation and after adding the reinforcement, performing subsequent plastic deformation by pressing the pressure and suction side sheets against an outside surface of the core after the sheets have been closed around the core, and extracting the core.

Disclosed is a method for producing a blade for a turbomachine, in particular for an aero engine. The method comprises providing at least one blade airfoil with a first platform region and at least one blade root with a second platform region and joining the blade airfoil and the blade root at the respective platform regions by a friction welding method at a common joint region of the platform regions, the blade airfoil and the blade root being made of materials which are different from each other. Also disclosed is a blade which is and/or can be obtained by such a method.