Layered structures with integral brazing materials

Abstract

A layered structure comprising a base structure having a major surface, and a brazing layer secured to the major surface of the base structure, where the brazing layer is applied to the major surface prior to positioning the layered structure in contact with a turbine engine component.

1 . A layered structure for use with a turbine engine component, the layered structure comprising:
 a base structure having a major surface; and   a brazing layer secured to the major surface of the base structure, the brazing layer being applied to the major surface prior to positioning the layered structure in contact with the turbine engine component.   
   
   
       2 . The layered structure of  claim 1 , wherein the brazing layer has a thickness ranging from about 25 micrometers to about 250 micrometers. 
   
   
       3 . The layered structure of  claim 2 , wherein the thickness of the brazing layer ranges from about 25 micrometers to about 130 micrometers. 
   
   
       4 . The layered structure of  claim 1 , wherein the turbine engine component is selected from the group consisting of high pressure turbine blades, low pressure turbine blades, high pressure turbine vanes, low pressure turbine vanes, blade outer airseals, shrouds, bearing housings, ducts, and supports. 
   
   
       5 . The layered structure of  claim 1 , wherein the major surface is a first major surface and the brazing layer is a first brazing layer, wherein the base structure also has a second major surface opposite the first major surface, and wherein the layered structure further comprises a second brazing layer secured to the second major surface of the base structure. 
   
   
       6 . The layered structure of claim ˜1, wherein the brazing layer is derived from a brazing material selected from the group consisting of nickel, nickel-based alloys, nickel-based superalloys, cobalt, cobalt-based alloys, cobalt-based superalloys, and combinations thereof. 
   
   
       7 . A method for manufacturing a turbine engine component, the method comprising:
 providing a layered structure having a major surface and a brazing layer secured to the major surface;   positioning the layered structure onto a turbine engine component surface such that at least a portion of the brazing layer contacts the turbine engine component surface;   heating the turbine engine component containing the layered structure; and   cooling the turbine engine component, thereby fusing the layered structure to the turbine engine component with the brazing layer.   
   
   
       8 . The method of  claim 7 , further comprising:
 coating a brazing material onto the major surface of the layered structure; and   fusing the brazing material to the layered structure.   
   
   
       9 . The method of  claim 7 , wherein heating the turbine engine component containing the layered structure comprises heating the turbine engine component to a temperature ranging from about 1200° C. to about 1260° C. 
   
   
       10 . The method of  claim 7 , wherein the major surface is a first major surface and the brazing layer is a first brazing layer, wherein the layered structure also has a second major surface opposite the first major surface, and wherein the layered structure further comprises a second brazing layer secured to the second major surface. 
   
   
       11 . The method of  claim 7 , further comprising:
 coating a brazing material onto a master sheet;   fusing the brazing material to the master sheet; and   separating the master sheet into multiple plates, the layered structure being one of the multiple plates.   
   
   
       12 . The method of  claim 7 , wherein the brazing layer has a thickness ranging from about 25 micrometers to about 250 micrometers. 
   
   
       13 . The method of  claim 12 , wherein the thickness of the brazing layer ranges from about 25 micrometers to about 130 micrometers. 
   
   
       14 . The method of  claim 7 , wherein the brazing layer is derived from a brazing material selected from the group consisting of nickel, nickel-based alloys, nickel-based superalloys, cobalt, cobalt-based alloys, cobalt-based superalloys, and combinations thereof. 
   
   
       15 . A method for manufacturing an airfoil component, the method comprising:
 determining an amount of brazing material required to perform a brazing operation;   coating a brazing material onto the major surface of the cover plate; and   fusing the brazing material to the cover plate to form a brazing layer having a thickness based at least in part on the determined amount of brazing material;   positioning the cover plate such that at least a portion of the brazing layer contacts an airfoil component surface; and   brazing the airfoil component containing the cover plate.   
   
   
       16 . The method of  claim 15 , wherein brazing the airfoil component containing the cover plate comprises:
 heating the airfoil component containing the cover plate comprises heating the airfoil component to a temperature ranging from about 1200° C. to about 1260° C.; and   cooling the heated airfoil component.   
   
   
       17 . The method of  claim 15 , wherein the thickness of the brazing layer ranges from about 25 micrometers to about 250 micrometers. 
   
   
       18 . The method of  claim 17 , wherein the thickness of the brazing layer ranges from about 25 micrometers to about 130 micrometers. 
   
   
       19 . The method of  claim 15 , wherein the major surface is a first major surface and the brazing layer is a first brazing layer, wherein the cover plate also has a second major surface opposite the first major surface, and wherein the cover plate further comprises a second brazing layer secured to the second major surface. 
   
   
       20 . The method of  claim 15 , wherein the brazing layer is derived from a brazing material selected from the group consisting of nickel, nickel-based alloys, nickel-based superalloys, cobalt, cobalt-based alloys, cobalt-based superalloys, and combinations thereof.