Patent Application
20070087129
The present disclosure generally relates to a method for repairing a workpiece, and more particularly, a method for repairing a workpiece using a microplasma spray coating.
Generally, conventional plasma spray coating apparatus are imprecise in applying their plasma spray coatings due to the size and width of the plasma stream. The plasma spray coating process typically requires the workpiece to be masked in areas where the material transfer is not desired and/or not required. Conventional plasma spray coating methods and apparatus require masking the workpiece and applying the coating due to the plasma spray coating pattern being too wide to accurately control the coating process. Such operating conditions inhibit and/or render difficult the ability to spot coat workpieces in order to form a deposit and replace or augment parent material.
Consequently, there exists a need for a method for repairing a workpiece using a microplasma spray coating capable of being applied as a spot coating without the need for masking while still providing acceptable spray coating quality.
In accordance with the present invention, a method for repairing a workpiece broadly comprises providing an unstripped, coated workpiece broadly comprising a surface having a localized damage site; masking the workpiece about the localized damage site; generating a microplasma stream; applying a first powdered material to the localized damage site using the microplasma stream; and applying a second powdered material to the workpiece surface using the microplasma stream.
In accordance with the present invention, a method for repairing an unstripped, coated workpiece broadly comprises providing a workpiece comprising a surface having a localized damage site; generating a microplasma stream; applying without a maskant a powdered metal alloy to the localized damage site using the microplasma stream; and dimensionally restoring the workpiece.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
Like reference numbers and designations in the various drawings indicate like elements.
In performing the method(s) described herein, it is contemplated that a stationary microplasma spray coating apparatus, automated microplasma spray coating apparatus, remote controlled microplasma spray coating apparatus, robotic or robot implemented microplasma spray coating apparatus, and portable microplasma spray coating apparatus may be utilized. The stationary, automated, remote controlled and robotic implemented models are typically utilized within an enclosure such as a dedicated room where the ultra violet light level may be controlled and excess microplasma spray and/or powdered material may be collected with ease. It is also contemplated that a portable microplasma spray coating apparatus may be mounted on a mobile platform such as a vehicle, and transported to on-site locations to quickly facilitate repair work. Such a portable microplasma spray coating apparatus is described in U.S. patent application Ser. No. 11/190,135, Attorney Docket No. 05-199, assigned to United Technologies Corporation, the assignee of record herein, which is incorporated herein by reference as if set forth at length.
In the exemplary embodiment, the cathode 18 is held within and extending from an insulated body 26 of a cathode cartridge or assembly 28. The exemplary cartridge 28 also includes threads 30 for threadingly engaging the microplasma gun body. The exemplary cathode 18 also includes an 0-ring seal 32 to seal the leak path that is created at the interface between the cartridge 28 and the microplasma gun body.
In operation, an electric arc 20 (
A powdered material injector 22 injects powdered material 34 into the plasma gas stream 21. The powdered material 34 is heated to a super-plastic state in the plasma stream and is deposited on the blade (
A nozzle shroud 46 positioned on a forward wall 48 of the microplasma gun 12 holds a nozzle insert 50 and permits the electrode 28 to extend through a center aperture 52 formed in the nozzle shroud 46. The nozzle insert 50 can be threadingly attached to an end of the nozzle shroud 46. A shield gas cap 54 is positioned adjacent the nozzle shroud 46. An insulator 56 is positioned between the shield gas cap 54 and the nozzle shroud 46 to electrically isolate the shield gas cap 54 from the nozzle shroud 46. The shield gas cap 54 can be pressed to fit onto the nozzle shroud 46 and over the insulator 56. The shield gas cap 54 includes a plurality of through apertures 58 for permitting shield gas to flow therethrough and shield the arc gas from ambient atmosphere. A center aperture 60 formed in the shield gas cap 54 permits high velocity arc gas to pass through and into the electric arc.
Cooling fluid, such as water or the like, may be utilized to cool the microplasma gun 12. The cooling fluid is delivered to the microplasma gun 12 via a cooling fluid hose 62. The cooling fluid traverses through internal passages (not shown) in the microplasma gun 12 and flows through an inlet passage 64, into an anode holder 66 and back through an outlet passage 68. The cooling fluid reduces the temperature of the anode 16 during operation of the microplasma gun 12. The cooling flow rate may be approximately 0.1 to 1 gallons per minute. A second conduit 70 is connected to the microplasma gun 12. The second conduit may be operable for providing electrical power, arc gas, and shield gas to the microplasma gun 12.
The microplasma gun 12 may be operated at a relatively low power range of between approximately 0.5 Kilowatts and 4 Kilowatts. The low power output of the microplasma gun 12 significantly reduces the heat flow into the blade 72 over that of conventional coating methods. The maximum surface temperature of the blade 72 caused by the coating process is approximately 200° F. depending on the mass of the blade. The microplasma gun 12 is operable for applying powdered material 34 to a thin wall area of the blade 72 without distorting the blade 72 because the low power output limits the localized stress caused by high thermal gradients.
The powder hopper 36 holds the powdered material 34 prior to being injected into the plasma gas stream 21 by the powder injector 22. The powdered material 34 can be injected into the plasma gas stream 21 either through gravity feed or through a pressurized system (not shown). The shut-off control valve 42 controls the powdered material 34 feed rate into the plasma gas stream 21. Powdered material 34 is transferred to the blade 72 at an approximately 1 to 30 grams per minute. When employing a pressurized system, the powder gas flow may be at approximately 0.1 to 1.5 liters per minute. Generally, the microplasma gun 12 may be positioned from a component to be coated at a distance of approximately 1.5 inches (3.8 centimeters) to 8 inches (20 centimeters). The microplasma gun 12 may apply the material from exemplary distances of approximately 2.5 inches (6.4 centimeters) to 6.5 inches (16.5 centimeters) to the blade 72, or other components, but can vary depending on the coating application requirements. The exemplary microplasma spray gun 12 can be oriented between a positive 45° angle and a negative 45° angle relative to a normal axis of the blade and still provide adequate material delivery with a gravity feed system. A pressure feed system may provide greater orientational freedom for the microplasma gun 12. The microplasma spray gun 12 advantageously generates a relatively low noise level that ranges (e.g., 40-70 dB) due to the low power output, thereby making the apparatus 10 suitable for hand held application. Current U.S. government regulations require hearing protection when environmental noise reaches 85 dB. The microplasma spray apparatus 10 can be hand held or alternatively held in an automated fixture (not shown) that is computer controlled.
The microplasma gun 12 can apply the material in small spots (e.g., about 1 millimeter to about 5 millimeters in diameter) or apply a stream of material in a sweeping motion to form narrow strips (e.g., about 0.5 millimeters to about 5 millimeters in width). For purposes of the intended application, the microplasma gun preferably applies material in small spots to repair coating chips. This permits accurate surface coating even with a hand held device. The small spot/strip size may substantially eliminate the need for masking or otherwise covering the blade 72 in areas where the material is unwanted. The nozzle opening size controls the spray pattern. The hand-held version of the microplasma gun 12 may be sufficiently accurate that material can be sprayed on components while they remain installed in an engine or the like.
An exemplary arc gas flow rate of the microplasma apparatus 10 may be about 0.5 to about 3 liters per minute. As stated above, the arc gas and shield gas are typically argon, but any suitable inert gas can be utilized. An exemplary shield gas flow rate ranges may be about 2 to about 8 liters per minute for a typical application.
For purposes of illustration, and not to be taken in a limiting sense, the methods for repairing workpieces contemplated herein will be described with respect to using the aforementioned portable, hand-held microplasma spray coating apparatus. It is contemplated as will be recognized by one of ordinary skill in the art that the aforementioned portable, hand-held microplasma apparatus may be outfitted for use in the aforementioned stationary, automated, remote controlled and robotic implemented models. It is contemplated that the workpieces may comprise various gas turbine engine and turbomachinery components related, but not limited to, a fan, turbine, compressor, vane, blade, casing, combustion chamber, combustor panel, seals, rings, and the like, as well as other similar components in other industrial applications.
As used herein, the term “coated workpiece” means a turbine engine component having at least one layer of coating covering the entire surface or substantially the entire surface of the part. As used herein, the term “unstripped, coated workpiece” means a coated workpiece whose coating layer(s) have not been stripped off or removed to expose the workpiece surface or intermediate layers of coating. As used herein, the term “localized damage site” represents an exposed portion of an intermediate layer of coating and/or the workpiece surface. As used herein, the term “unstripped, coated workpiece having a localized damage site” means a coated workpiece having a localized damage site surrounded by the remaining coating layers.
The powdered material may be provided as a single powder of a single alloy as a mechanical blend or multiple alloys either pre-mixed or mixed by the apparatus. The component powders may be selected in view of the workpiece properties. The workpiece may comprise a nickel-based alloy, a cobalt-based alloy, a ferrous-based alloy such as steel, a titanium-based alloy, an aluminum-based alloy, and combinations thereof. The apparatus may be used to form a deposit for replacing parent material lost from the substrate (e.g., due to damage plus cleaning and preparation) or to augment (e.g., fill a manufacturing defect, coat with a dissimilar material, or otherwise).
The workpiece may comprise any component used in operating conditions where a protective coating is necessary to withstand, for example, burn-through, diffusion-controlled deformation (“creep”), cyclic loading and unloading (“fatigue”), chemical attack by hot gas flow (“oxidation”), wear from contact with other parts, wear from the impact of particles entrained in the gas flow (“erosion”), foreign object damage (“FOD”), dimensional restoration, and the like. For purposes of illustration, and not to be taken in a limiting sense, the workpiece may be a gas turbine engine blade. In addition, the workpiece may comprise any of the aforementioned gas turbine engine and turbomachinery components. Gas turbine engine components and associated hot section hardware are typically coated with a metallic coat alone or a metallic bond coat and a ceramic top coat. Accordingly, the aforementioned gas turbine engine components may have dimensions restored with various metallic coatings.
The metallic bond coat may comprise any suitable bond coat known in the art. For example, the bond coat may be formed from an aluminum containing material, e.g., nickel aluminum; an aluminide, e.g., a platinum aluminide; or an MCrAlY material where M includes, but is not limited to, nickel, cobalt, or other alloys, which are well known in the art. The ceramic top coat may comprise a thermal barrier coating comprising, for example, yttria stabilized zirconia. Representative thermal barrier coatings may include, but are not limited to, those described in, for example, U.S. Pat. No. 4,861,618 to Vine et al., assigned to United Technologies Corporation, and incorporated by referenced herein as if set forth at length.
The metallic bond coat may be applied to the damage site 73. Such precise spot or chip repair is possible due to the narrow microplasma stream being generated. The metallic bond coat material adheres to the workpiece substrate material. A maskant or masking agent in minimal amounts is commonly utilized to prevent the area surrounding the damage site 73 from receiving additional metallic bond coat material. The ceramic top coat may then be applied as a full ceramic coat, that is, applied on the damage site 73 and the entirety of the surface of the blade 72. The added materials strengthen the area under repair by substantially reinforcing the eroded/machined repair surface. For example, the coating may serve to provide wear resistance to the damaged site. The repair site, when fully processed (e.g., by heat treatment processing) has properties approaching those of the original coated parent part surface.
While the methods have been described with respect to spot repair of thermal barrier coatings on various components, the methods also apply to spot repairs of various single layer metallic coatings for dimensional restoration of gas turbine engine and combustion chamber components such as fans, compressors, turbine casings, seals, plates, rings and the like. This dimensional restoration method provides an opportunity to repair a local area without having to strip the entire coating from the part and recoat the part's entire surface.
Microplasma spray may be used for the dimensional restoration or “chip repair” of various single layer metallic coatings upon the aforementioned components. The powdered material for use in the microplasma spray may comprise a metal alloy. Suitable metal alloys for dimensional restoration include, but are not limited to, nickel-aluminum, nickel-chromium (e.g., Inconel 718), nickel chromium-aluminum, molybdenum, aluminum-silicon, and the like. Suitable materials for wear resistance, e.g., in chip repair, include, but are not limited to, the carbides of such suitable metal alloys for dimensional restoration. All of the aforementioned metal alloys are often used for the dimensional restoration of components comprising a wide variety of nickel-base alloy, steels, cobalt-base alloy, titanium-base alloy and aluminum-base alloy components, respectively.
This spot application may permit a localized repair of the coating without having to strip the entire coating from the part and re-coat. For example, a spot application of nickel-chrome-chromium carbide, which is used for high temperature wear resistance on various seals, plates, and rings, may similarly reduce the need to remove previously applied coating from the entire part and re-coat.
Using a microplasma stream as described, the powdered metal alloy may be applied as a single layer metallic coating to the damage site 73. Such precise spot or chip repair is possible due to the narrow microplasma stream being generated. The powdered metal alloy adheres to the substrate material. Optionally, a maskant or masking agent in minimal amounts may be utilized to prevent the area surrounding the damage site 73 from receiving excess powdered metal alloy. The added materials strengthen the area under repair by substantially reinforcing the eroded/machined repair surface and providing dimensional restoration. The repair site, when fully processed (e.g., by heat treatment processing) has properties approaching those of the original coated parent part surface.
It is to be understood that the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention, and which are susceptible to modification of form, size, arrangement of parts, and details of operation. The invention rather is intended to encompass all such modifications which are within its spirit and scope as defined by the claims.
