Patent Application
20080028605
The systems and methods of the present invention are described herein below with reference to various figures, in which:
For the purposes of promoting an understanding of the invention, reference will now be made to some preferred embodiments of this invention as illustrated in
This invention comprises methods for repairing a damaged metallic component (i.e., damage to the platform area of previously unrepairable industrial gas turbine blades). Embodiments of this invention provide controlled repair of worn, eroded or otherwise damaged areas of these components to meet precise dimensional and metallurgical requirements. These methods create robust repaired components that can be returned to service in an engine.
As shown in
In embodiments, these turbine blades may be made of various commercially available alloys, such as the nickel based superalloys PWA 1483, GTD-111®, and/or IN-738. The damage that can be repaired may include cracks, corrosion, erosion, burned areas, foreign object damage (FOD), or any other type of damage that might occur to the platform area of such blades.
In step 10, the coatings may be removed from the desired locations in any suitable manner, such as by grit blasting, machining, belting with abrasives, chemical stripping, waterjet blasting and/or autoclave processing, etc., either alone or in combination. For example, in one non-limiting embodiment, a ceramic coating and McrAlY bond coat may both need to be removed from the area proximate the damage. In some embodiments, the coating(s) on the entire turbine blade may be removed, while in other embodiments, only the coating(s) in the area proximate the damage may be removed. If desired, after coating removal, the component may be cleaned of any residual oxides, debris, organic contaminants, etc. in any suitable manner, such as by vacuum and/or hydrogen heat treating, grinding, rinsing with aqueous or organic solvents, etc.
Next, in step 12, the damage may be removed from the component in any suitable manner, such as by blending, grinding and/or machining away the portion of the platform containing the damage. It has been determined that embodiments of this invention may be used to remove and repair damage to the platform as deep D as 0.300 inches.
Next, in step 14, the component can be weld repaired to restore the dimensions of the component back to at least the original dimensions of the component. Any suitable type of welding may be used to build up the dimensions of the component, such as, gas tungsten arc welding (TIG welding), laser welding, etc. This weld build up may utilize any suitable type of weld filler material, such as for example, commercially available PWA 795 (a cobalt based MERL 72 material), Inconel 617, IN-939, and/or Inconel 625, either in powder or weld wire form. In one non-limiting embodiment, PWA 795 weld wire having a diameter of about 0.045 inches may be utilized with TIG welding to build the dimensions of the component back up.
Next, in step 16, the dimensions of the repaired component can be returned to the dimensions of the original component in any suitable manner, such as by machining, grinding, blending, etc.
Next, in step 18, the repaired component can be heat treated in any suitable manner to relieve stresses in the component. In embodiments, the component can be heat treated at about 2050-2175° F. for about 2-4 hours, preferably at about 2050° F. for about 4 hours. This heat treating may occur in a vacuum, preferably at about 5×104 torr minimum. After the heat treatment is carried out at the desired temperature for the desired period of time, the component can be cooled in any suitable manner. In some embodiments, the component may be rapidly quenched to below about 1000° F. In other embodiments, the component may be cooled to below about 1000° F. at a controlled rate of about 3-40° F./minute.
Next, in step 20, the component can be inspected in any sutiable manner, such as by fluorescent penetrant inspection (FPI), to ensure that the damage/defect has been sufficiently repaired.
Next, in step 22, the component can be recoated in the areas where needed in any suitable manner. In embodiments, this step may include applying a ceramic coating on the component, either with or without a bond coat between the component and the ceramic coating. Any suitable bond coat and/or ceramic coatings may be used. In embodiments, the bond coat may comprise a nickel based alloy such as PWA 1386, which can be applied to the component via a low pressure plasma spray (LPPS) or high velocity oxy fuel (HVOF) process. In embodiments, the ceramic coating may comprise a yttrium oxide stabilized zirconium oxide material such as PWA 1375, which can be applied to the component via air plasma spray (APS).
Referring now to
Referring now to
As described above, this invention provides systems and methods for repairing metallic components, particularly damaged turbine blades. Advantageously, these systems and methods allow previously unrepairable components to be repaired. Many other embodiments and advantages will be apparent to those skilled in the relevant art.
Various embodiments of this invention have been described in fulfillment of the various needs that the invention meets. It should be recognized that these embodiments are merely illustrative of the principles of various embodiments of the present invention. Numerous modifications and adaptations thereof will be apparent to those skilled in the art without departing from the spirit and scope of the present invention. Thus, it is intended that the present invention cover all suitable modifications and variations as come within the scope of the appended claims and their equivalents.
