Hybrid additive manufacturing methods using hybrid additively manufactured features for hybrid components

Abstract

A hybrid additive manufacturing method comprises building an additive structure on a pre-sintered preform base, wherein building the additive structure comprises iteratively fusing together a plurality of layers of additive material with at least a first layer of additive material joined to the pre-sintered preform base, and wherein the pre-sintered preform base comprises an initial shape. The hybrid additive manufacturing method further comprises modifying the initial shape of the pre-sintered preform base comprising the additive structure into a modified shape comprising the additive structure, and, joining the pre-sintered preform base in its modified shape to a component.

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         11 . A hybrid additively manufactured feature comprising:
 a pre-sintered preform base comprising a modified shape different than an initial shape; and,   an additive structure joined to the pre-sintered preform base, wherein the additive structure was built on the pre-sintered preform while in its initial shape by fusing together a plurality of layers of additive material with at least a first layer of additive material joined to the pre-sintered preform base while in its initial shape.   
     
     
         12 . The hybrid additively manufactured feature of  claim 11 , wherein the modified shape comprises a non-planar surface. 
     
     
         13 . The hybrid additively manufactured feature of  claim 12 , wherein the initial shape comprised a planar surface. 
     
     
         14 . The hybrid additively manufactured feature of  claim 12 , wherein the non-planar surface comprises a curved surface. 
     
     
         15 . The hybrid additively manufactured feature of  claim 11 , wherein the additive structure comprises one or more cooling feature extensions. 
     
     
         16 . A hybrid component comprising:
 a pre-sintered preform base joined to a component, the pre-sintered preform base comprising a modified shape different than an initial shape; and,   an additive structure joined to the pre-sintered preform base, wherein the additive structure was built on the pre-sintered preform base while in its initial shape by fusing together a plurality of layers of additive material with at least a first layer of additive material joined to the pre-sintered preform base while in its initial shape.   
     
     
         17 . The hybrid component of  claim 16 , wherein the modified shape comprises a non-planar surface. 
     
     
         18 . The hybrid component of  claim 16 , wherein the component comprises a turbine component. 
     
     
         19 . The hybrid component of  claim 18 , wherein the turbine component comprises a nozzle, and wherein the pre-sintered preform base is joined to an interior surface of the nozzle. 
     
     
         20 . The hybrid component of  claim 16 , wherein the additive structure comprises one or more cooling feature extensions.