Solidification of an article extension from a melt using a ceramic mold

摘要

A method for forming integral extensions on the end of directionally oriented, superalloy articles, such as airfoil blading members or other components used in gas turbine or other turbine engines. An extension (20) is formed directly on an article (2) by dipping a portion or end (4) of the article into a molten bath (26) of a compatible alloy, followed by withdrawal of the end under controlled conditions sufficient to cause an integral extension to solidify on the article. A ceramic mold (16) is utilized over the dipped end of the article with a mold cavity that generally defines the shape of the extension to be formed. The mold may be formed in situ, or preformed and attached to the subject article. Extensions formed by the method of this invention have a microstructure (29) that is continuous and compatible with that of the article. Such microstructures may include epitaxial growth of the extension from the microstructure (10) of the article. The method establishes a temperature gradient within the article during solidification that may be further controlled by auxiliary heating and/or cooling of the article and/or extension during the practice of the method.