Method of forming hybrid metal ceramic components

Abstract

A monolithic composite turbine component includes at least one first region of a first material and one second region of a second material formed by solid freeform fabrication (SFF). The first material may be a metal and the second material may be a ceramic or a ceramic matrix composite. Transition regions between the metal region and ceramic region are functionally graded regions to minimize internal stress during temperature fluctuations.

1 . A monolithic composite turbine component comprising:
 at least one first region of a first material;   at least one second region of a second material; and   at least one functionally graded transition region of the first material and the second material between a first region and a second region of the component   
     
     
         2 . The component of  claim 1  wherein the first material is a metal. 
     
     
         3 . The component of  claim 1  wherein the second material is a ceramic or a ceramic matrix composite. 
     
     
         4 . The component of  claim 1  wherein the component is formed by a solid freeform (SFF) additive manufacturing process. 
     
     
         5 . The component of  claim 4  wherein the solid freeform (SFF) additive manufacturing process is selective laser melting (SLM). 
     
     
         6 . The component of  claim 1  wherein the component is a nozzle or a vane 
     
     
         7 . The component of  claim 1  wherein the component is a rotating airfoil, bucket, or blade. 
     
     
         8 . The component of  claim 1  wherein the component is a combustor panel, combustor heat shield, or combustor fuel nozzle. 
     
     
         9 . The component of  claim 2  wherein the metal is selected from the group consisting of nickel base, iron base, cobalt base superalloy, titanium, and titanium alloy. 
     
     
         10 . The component of  claim 3  wherein the ceramic is selected from the group consisting of silicon carbide, silicon nitride, silicon oxynitride, and aluminum oxide. 
     
     
         11 . The component of  claim 3  wherein the ceramic matrix composite is selected from the group consisting of SiC/SiC, C/SiC, and SiC/Si. 
     
     
         12 . A method of forming a monolithic composite turbine component containing separate regions of different materials comprising:
 forming at least one first region of a first material;   forming a graded transition region on the first region with composition of the transition region changing from a first material to a second material as the forming of the transition region progresses; and   forming a second region of a second material on the transition region.   
     
     
         13 . The method of  claim 12  wherein the first material is a metal. 
     
     
         14 . The method of  claim 12  wherein the second material is a ceramic or ceramic matrix composite. 
     
     
         15 . The method of  claim 12  wherein forming comprises solid freeform (SFF) additive manufacturing. 
     
     
         16 . The method of  claim 15  wherein additive manufacturing comprises direct laser melting. 
     
     
         17 . The method of  claim 13  where the metal is selected from a group consisting of nickel base, iron base and cobalt base superalloy, titanium and titanium alloy. 
     
     
         18 . The method of  claim 14  wherein the ceramic is selected from the group consisting of silicon carbide, silicon nitride, silicon oxynitride, and aluminum oxide. 
     
     
         19 . The method of  claim 14  wherein the ceramic matrix composite is selected from the group consisting of SiC/SiC, C/SiC, and SiC/Si. 
     
     
         20 . The method of  claim 12  wherein the component is a nozzle, vane, rotating airfoil, bucket, blade, combustor panel, combustor heat shield, or combustor fuel nozzle.