Composite component having angled braze joint, coupon brazing method and related storage medium

Abstract

Various aspects include a composite component (also known as a Shear Enabled Regionally Engineered Facet (SEREF)) and methods of forming such a component. In some cases, a method includes: forming a slot in a main body of a metal alloy component, the slot extending at least partially through a wall of the metal alloy component, the forming of the slot including forming an angled main body interface in the wall of the metal alloy component; forming a coupon for coupling with the slot in the metal alloy component, the coupon having an angled coupon interface complementing the angled main body interface; and brazing the coupon to the main body at the slot to form a composite component.

We claim: 
     
         1 . A method comprising:
 forming a slot in a main body of a metal alloy component, the slot extending at least partially through a wall of the metal alloy component, the forming of the slot including forming an angled main body interface in the wall of the metal alloy component;   forming a coupon for coupling with the slot in the metal alloy component, the coupon having an angled coupon interface complementing the angled main body interface; and   brazing the coupon to the main body at the slot to form a composite component.   
     
     
         2 . The method of  claim 1 , wherein the metal alloy component includes a high-gamma prime alloy or a brittle alloy including: René 125, René 80, René N5, René N4, Rene 108, GTD-111, GTD-444, Inconel (IN) 738, IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4, PWA1480, PWA1483, or PWA1484. 
     
     
         3 . The method of  claim 1 , wherein the metal alloy component is a previously commissioned component exposed to operation within a machine. 
     
     
         4 . The method of  claim 1 , wherein the angled main body interface and the angled coupon interface have an angle between approximately 10 degrees and approximately 45 degrees, as measured from a plane coincident with an outer surface of the main body. 
     
     
         5 . The method of  claim 1 , wherein the angled main body interface and the angled coupon interface have an angle between approximately 10 degrees and approximately 25 degrees, as measured from a plane coincident with an outer surface of the main body. 
     
     
         6 . The method of  claim 1 , wherein the forming of the slot in the main body includes cutting the metal alloy component, and wherein forming the coupon includes casting or additively manufacturing the coupon. 
     
     
         7 . The method of  claim 1 , wherein the main body has an outer surface, and the coupon has:
 a larger diameter (LD) spanning the slot across the outer surface of the main body; and   a smaller diameter (SD) spanning the slot across an inner surface of the main body, wherein the LD is defined by:
     LD= ((2* Z )/tan α)+ SD  
 
   wherein Z=a thickness of the wall and α=an angle of the angled main body interface and the angled coupon interface, as measured relative to a plane coincident with the outer surface of the main body.   
     
     
         8 . The method of  claim 1 , wherein the angled main body interface and the angled coupon interface are configured to bear a predominately shear stress in response to application of tension on the composite component. 
     
     
         9 . The method of  claim 1 , wherein the composite component includes a turbomachine component. 
     
     
         10 . The method of  claim 1 , wherein the coupon includes the metal alloy or a distinct metal alloy from the metal alloy of the metal alloy component. 
     
     
         11 . The method of  claim 1 , further comprising performing a hot isostatic pressure (HIP) heat treatment (HT) on the composite component after the brazing. 
     
     
         12 . A method comprising:
 forming a slot in a main body of a metal alloy component, the slot extending at least partially through a wall of the main body, wherein the wall has an inner surface and an outer surface, the forming of the slot including forming an angled main body interface in the wall of the main body;   forming a coupon for coupling with the slot in the main body, the coupon having an angled coupon interface complementing the angled main body interface, wherein the coupon has: a larger diameter (LD) spanning the slot across the outer surface of the main body; and a smaller diameter (SD) spanning the slot across an inner surface of the main body; and   brazing the coupon to the main body at the slot to form a composite component.   
     
     
         13 . The method of  claim 12 , wherein the LD is defined by:
     LD= ((2* Z )/tan α)+ SD  
   wherein Z=a thickness of the wall and α=an angle of the angled main body interface and the angled coupon interface, as measured from a plane coincident with the outer surface of the main body   
     
     
         14 . The method of  claim 12 , wherein the metal alloy component includes a high-gamma prime alloy or a brittle alloy including: René 125, René 80, René N5, René N4, René 108, GTD-111, GTD-444, Inconel (IN) 738, IN792, MAR-M200, MAR-M247, CMSX-3, CMSX-4, PWA1480, PWA1483, or PWA1484. 
     
     
         15 . The method component of  claim 12 , wherein the angle a is between approximately 10 degrees and approximately 45 degrees, as measured from the plane coincident with the outer surface of the main body. 
     
     
         16 . The method component of  claim 12 , wherein the angle a is between approximately 10 degrees and approximately 25 degrees, as measured from the plane coincident with the outer surface of the main body. 
     
     
         17 . The method component of  claim 12 , wherein the angled main body interface and the angled coupon interface are configured to bear a predominately shear stress in response to application of tension on the composite component. 
     
     
         18 . The method component of  claim 12 , wherein the composite component includes a turbomachine component. 
     
     
         19 . The method component of  claim 12 , wherein the coupon includes the metal alloy or a distinct metal alloy from the metal alloy of the metal alloy component. 
     
     
         20 . A method comprising:
 forming a slot in a main body of a metal alloy component, the slot extending at least partially through a wall of the main body, wherein the wall has an inner surface and an outer surface, the forming of the slot including forming an angled main body interface in the wall of the main body;   forming a coupon for coupling with the slot in the main body, the coupon having an angled coupon interface complementing the angled main body interface, wherein the coupon has a larger diameter (LD) spanning the slot across the outer surface of the main body; and a smaller diameter (SD) spanning the slot across an inner surface of the main body, wherein the LD is defined by:
     LD= ((2* Z )/tan α)+ SD  
 
   wherein Z=a thickness of the wall and α=an angle of the angled main body interface and the angled coupon interface, as measured from a plane coincident with the outer surface of the main body; and   brazing the coupon to the main body at the slot to form a composite component.