A gas turbine engine assembly according to an example of the present disclosure includes, among other things, an endwall having a first material composition, an airfoil extending in a radial direction from the endwall, and a cupped contour of a second material composition that is formed on the endwall to define a cooling chamber, the first material composition different than the second material composition. A method of forming an endwall is also disclosed.

A method of manufacturing a hard-to-weld material by a beam-assisted additive manufacturing process is presented. The method includes depositing a first layer for the material onto the substrate, the first layer including a major fraction of a base material for the component and a minor fraction of a solder, depositing a second layer of the base material for the component and a thermal treatment of the layer arrangement. The thermal treatment includes a first thermal cycle at a first temperature above 1200° C. for a duration of more than 3 hours, a subsequent second thermal cycle at a second temperature above 1000° C. for more than 2 hours, and a subsequent third thermal cycle and a third temperature above 700° C. for more than 12 hours. A manufactured component is also presented.

A method of manufacturing a hard-to-weld material by a beam-assisted additive manufacturing process is presented. The method includes depositing a first layer for the material onto the substrate, the first layer including a major fraction of a base material for the component and a minor fraction of a solder, depositing a second layer of the base material for the component and a thermal treatment of the layer arrangement. The thermal treatment includes a first thermal cycle at a first temperature above 1200° C. for a duration of more than 3 hours, a subsequent second thermal cycle at a second temperature above 1000° C. for more than 2 hours, and a subsequent third thermal cycle and a third temperature above 700° C. for more than 12 hours. A manufactured component is also presented.

An airfoil vane includes an airfoil section which includes an outer wall that defines an internal cavity. A baffle is situated in the internal cavity. The baffle includes a leading edge portion and a trailing edge portion which is bonded to the leading edge portion at a joint. The leading edge portion and the trailing edge portion define an internal cavity therewithin. Both the leading edge portion and the trailing edge portion include a plurality of cooling holes which are configured to provide cooling air to the airfoil outer wall. The trailing edge portion is formed of sheet metal and the leading edge portion is formed of non-sheet-metal. A method of making a baffle for a vane arc segment and a method of assembling a ceramic matrix composite airfoil vane are also disclosed.

Embodiments of bladed rotors and methods for manufacturing bladed rotors are provided herein. The method for manufacturing bladed rotors includes providing a workpiece including a first rotor blade segment. The first rotor blade segment includes a first platform portion on a radially outward end portion of the first rotor blade segment. Further, the method includes forming a second rotor blade segment, by additive manufacturing, removing a side portion of the first platform portion, and removing a side portion of the second rotor blade segment, whereby a second platform portion remains on a radially outward end portion of the second rotor blade segment.

Embodiments of bladed rotors and methods for manufacturing bladed rotors are provided herein. The method for manufacturing bladed rotors includes providing a workpiece including a first rotor blade segment. The first rotor blade segment includes a first platform portion on a radially outward end portion of the first rotor blade segment. Further, the method includes forming a second rotor blade segment, by additive manufacturing, removing a side portion of the first platform portion, and removing a side portion of the second rotor blade segment, whereby a second platform portion remains on a radially outward end portion of the second rotor blade segment.

A method for manufacturing a blade in composite material with added metal leading edge for gas turbine aeroengine, the method including producing a batch of plurality of blade bodies in composite material; creating a digital model of a blade body from a blade in the batch of plurality of blade bodies; creating a digital model of a theoretical final blade including a leading edge; generating a digital model of a leading edge from the digital model of a blade body and final blade model; manufacturing at least one leading edge via additive manufacturing from the generated leading edge digital model; bonding each manufactured leading edge onto a blade body from the batch of plurality of blade bodies.

The disclosure relates to an apparatus for manufacturing a metallic component, and corresponding methods. The apparatus may include a build plate with a build surface and an aperture. The apparatus may also include an actuator operable to translate a metallic component such that an end portion of the metallic component is positioned within the aperture of the build plate and below the build surface. The apparatus may further include a seal coupled within the aperture of the build plate and configured to engage the end portion of the metallic component. The aperture of the build plate, the seal, and the end portion of the metallic component may cooperate to form a powder bed to hold metallic powder therein. The apparatus may also include an external heat control mechanism operable to form a predetermined temperature profile of the end portion of the component to prevent cracking of the component.

A tooling assembly and method of aligning a plurality of components for a repair process in an additive manufacturing machine includes positioning the plurality of components such that a repair surface of each of the plurality of components contacts an alignment plate, e.g., under the force of gravity or using biasing members. The method further includes surrounding the alignment plate with containment walls to define a reservoir around the plurality of components and dispensing a fill material, such as wax or a potting material, into the reservoir which is configured for fixing a relative position of the plurality of components when the fill material is solidified.

A tooling assembly and method of aligning a plurality of components for a repair process in an additive manufacturing machine includes positioning the plurality of components such that a repair surface of each of the plurality of components contacts an alignment plate, e.g., under the force of gravity or using biasing members. The method further includes surrounding the alignment plate with containment walls to define a reservoir around the plurality of components and dispensing a fill material, such as wax or a potting material, into the reservoir which is configured for fixing a relative position of the plurality of components when the fill material is solidified.