A method for manufacturing a gas turbine engine component from a molybdenum-rich alloy. The method includes the steps of providing a molybdenum powder of at least 50% molybdenum by weight, extruding the molybdenum powder to provide a first shape, forming the first shape to a second shape and forging the second shape to provide a third shape.

An article includes a substrate formed of a molybdenum-based alloy. The molybdenum-based alloy has a composition that includes molybdenum, silicon, and boron. A barrier layer is disposed on the substrate. The barrier layer is formed of at least one noble metal.

Disclosed is an austenitic stainless steel alloy that includes, by weight, about 22% to about 28% chromium, about 3.5% to about 6.5% nickel, about 1% to about 6% manganese, about 0.5% to about 2.5% silicon, about 0.3% to about 0.6% carbon, about 0.2% to about 0.8% nitrogen, and a balance of iron. Molybdenum, niobium, and tungsten are excluded. The alloy is suitable for use in turbocharger turbine housing applications for temperature up to about 980 C.

A clearance control system for a gas turbine engine includes a full hoop blade outer air seal carrier ring, a full hoop thermal control ring at least partially contained within the full hoop blade outer air seal blade outer air seal carrier ring to form an interference fit therebetween, and a multiple of blade outer air seals mounted to the full hoop blade outer air seal carrier ring.

A clearance control system for a gas turbine engine includes a full hoop blade outer air seal carrier ring, a full hoop thermal control ring at least partially contained within the full hoop blade outer air seal blade outer air seal carrier ring to form an interference fit therebetween, and a multiple of blade outer air seals mounted to the full hoop blade outer air seal carrier ring.

It is an objective of the invention to provide a steam turbine rotor of which a rotor shaft is made of a low-cost heat resistant ferritic steel and that can withstand high main steam temperatures of about 650 C. There is provided a steam turbine rotor comprising: a rotor shaft made of a heat resistant ferritic steel such as a 12-Cr steel; and a rotor blade made of a TiAl alloy, wherein the TiAl alloy includes: from 38 to 45 atomic % of Al; from 0.5 to 2 atomic % of V; from 2 to 6 atomic % of Cr and/or Mo; and the balance being Ti and incidental impurities.

A gas turbine engine component includes an airfoil that has first and second structural airfoil segments that are bonded to each other in at least one diffusion joint. The first and second structural airfoil segments are formed of, respectively, first and second materials. The first and second materials are: different base-metal metallic alloys, a metallic alloy and a ceramic-based material, or ceramic-based materials that differ by at least one of composition and microstructure. The first structural airfoil segment is a first skin and the second structural airfoil segment is a hollow core that has an airfoil shape.

Various aspects include a composite turbomachine component and related methods. In some cases, a method includes: identifying a location of potential or actual structural weakness in a body of a turbomachine component, the body including a first material having a first thermal expansion coefficient; forming a slot in the location of the body, the slot extending at least partially through a wall of the turbomachine component; and bonding an insert to the body at the slot to form a composite component, the insert including a second material having a second thermal expansion coefficient differing from the first thermal expansion coefficient by up to approximately ten percent, the second material consisting of a nickel-chromium-molybdenum alloy, wherein after the bonding the insert is configured to reduce the potential or actual structural weakness in the body.

A method for forming a secondary component from an original component having an original shape includes separating the original component into a parent component and a replaced portion, and forming a replacement coupon using an additive manufacturing system. The replacement coupon is shaped to substantially match the original shape of the replaced portion. The method further includes coupling the replacement coupon to the parent component to form the secondary component. The method also includes at least one of (i) removing the replacement coupon from a build plate of the additive manufacturing system prior to application of any heat treatment to the as-built replacement coupon, wherein the replacement coupon maintains a near-net original shape of the replaced portion after removal, and (ii) entering the secondary component into normal duty with no hot isostatic press treatment of the replacement coupon having been performed.

A component includes a component body that is configured for use in a gas turbine engine. The component body includes first and second structural segments that are bonded to each other in at least one diffusion joint. The first and second structural segments are formed of, respectively, first and second materials. The first and second materials are different base-metal alloys, a metallic alloy and a ceramic-based material, or ceramic-based materials that differ by at least one of composition and microstructure.