WO2019177607A1 - Fabrication additive à fil de brasage laser d'un élément d'aube de turbine en super-solution avec refroidissement au-dessous de zéro - Google Patents

Fabrication additive à fil de brasage laser d'un élément d'aube de turbine en super-solution avec refroidissement au-dessous de zéro Download PDF

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Publication number
WO2019177607A1
WO2019177607A1 PCT/US2018/022532 US2018022532W WO2019177607A1 WO 2019177607 A1 WO2019177607 A1 WO 2019177607A1 US 2018022532 W US2018022532 W US 2018022532W WO 2019177607 A1 WO2019177607 A1 WO 2019177607A1
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WO
WIPO (PCT)
Prior art keywords
tip
temperature
cooling
braze
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2018/022532
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English (en)
Inventor
Ahmed Kamel
Kazim Ozbaysal
Zafir A. M. ABDO
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Siemens Energy Inc
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Siemens Energy Inc
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Publication date
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Priority to PCT/US2018/022532 priority Critical patent/WO2019177607A1/fr
Publication of WO2019177607A1 publication Critical patent/WO2019177607A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/60—Preliminary treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/0008—Soldering, e.g. brazing, or unsoldering specially adapted for particular articles or work
    • B23K1/0018—Brazing of turbine parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/005—Soldering by means of radiant energy
    • B23K1/0056—Soldering by means of radiant energy soldering by means of beams, e.g. lasers, electron beams [EB]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/19—Soldering, e.g. brazing, or unsoldering taking account of the properties of the materials to be soldered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B23K1/20—Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/14—Working by laser beam, e.g. welding, cutting or boring using a fluid stream, e.g. a jet of gas, in conjunction with the laser beam; Nozzles therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/70—Auxiliary operations or equipment
    • B23K26/702—Auxiliary equipment
    • B23K26/703—Cooling arrangements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering or brazing
    • B23K35/0227—Rods or wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering or brazing
    • B23K35/0244—Powders, particles or spheres; Preforms made therefrom
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
    • B23K35/3033—Ni as the principal constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
    • B23K35/3046—Co as the principal constituent
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/50—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for welded joints
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/005—Repairing methods or devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/001—Turbines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/08—Non-ferrous metals or alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00—Restoring or reconditioning objects
    • B23P6/002—Repairing turbine components, e.g. moving or stationary blades, rotors
    • B23P6/007—Repairing turbine components, e.g. moving or stationary blades, rotors using only additive methods, e.g. build-up welding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
    • F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
    • F05D2230/234—Laser welding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/20—Manufacture essentially without removing material
    • F05D2230/23—Manufacture essentially without removing material by permanently joining parts together
    • F05D2230/232—Manufacture essentially without removing material by permanently joining parts together by welding
    • F05D2230/237—Brazing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00—Manufacture
    • F05D2230/30—Manufacture with deposition of material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/10—Stators
    • F05D2240/12—Fluid guiding means, e.g. vanes
    • F05D2240/125—Fluid guiding means, e.g. vanes related to the tip of a stator vane
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2240/00—Components
    • F05D2240/20—Rotors
    • F05D2240/30—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor
    • F05D2240/307—Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor related to the tip of a rotor blade
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/17—Alloys
    • F05D2300/175—Superalloys

Definitions

  • the present disclosure relates generally to the field of materials technology, and more particularly, to additive manufacturing and braze repair methods for the repair of structural defects in superalloy components.
  • Gas turbine engine hot gas path components are typically formed of superalloy materials in order to withstand the high temperature, high stress environment to which they are exposed during operation of the engine.
  • superalloy is used herein as it is commonly used in the art; i.e., a highly corrosion and oxidation resistant alloy that exhibits excellent mechanical strength and resistance to creep at high temperatures.
  • superalloys typically include a high nickel or cobalt content. Examples of superalloys include alloys sold under the trademarks and brand names Hastelloy, Inconel alloys (e.g. IN 738, IN 792, IN 939), Rene alloys (e.g.
  • CMSX e.g. CMSX-4
  • Such components are very expensive to manufacture, and in spite of their superior material properties, they are prone to various forms of degradation during engine operation. Degraded components are removed from the engine and replaced. Depending upon the type and degree of degradation, used components may be refurbished and reused at a cost lower than the cost of a new component.
  • Nickel based superalloys are generally considered to be difficult to weld due to their tendency to grain boundary cracking.
  • Structural defects such as cracking typically occur when the material of the component cools after the weld procedure.
  • One cause of the cracking is due to a phase change taking place in the material during the cooling, which induces a thermal mismatch between the different phases causing stress in the component, particularly at the grain boundaries. This stress leads to the development of cracks in the material.
  • aspects of the present disclosure relate to a method of additively manufacturing or repairing a superalloy component and a system to additively manufacture or repair a superalloy component.
  • a first aspect provides a method of additively manufacturing or repairing a superalloy component.
  • the method provides at least a double solution heat treatment including initially heating the tip of the superalloy component to a first temperature for a first time period and then cooling the component to ambient temperature.
  • a second heat treatment is performed including heating the tip of the superalloy component to a second temperature for a second time period and then cooling the component to ambient temperature.
  • the tip of the superalloy component may then be laser braze repaired.
  • the laser braze repair includes depositing a layer of braze material on an end surface of the tip at a temperature less than the melting temperature of the composition of the base material of the component. Following the laser braze repair, the deposited layer is sub-cooled.
  • a second aspect provides a system to additively manufacture or repair a superalloy component.
  • the method described above may be performed utilizing the elements of the system.
  • the system comprises a heating system operably configured to produce heat up to and beyond a grain boundary melting temperature of the base metal of a tip of the superalloy component, a laser energy source operably configured to direct a laser energy towards a braze material melting the braze material and forming a deposited layer of additive material on the tip, and a sub-cooling means for sub-cooling the deposited layer.
  • Fig. 1 illustrates an exemplary embodiment of an additive manufacturing process or a laser braze repair process utilizing a sintered weld rod to additively deposit a layer of braze material
  • Fig. 2 illustrates an exemplary embodiment of a component being heated by a heating system.
  • Additive Manufacturing has recently been successfully used to ‘print’ or manufacture components directly layer by layer. This manufacturing technology enables the optimization of component design.
  • Additive manufacturing of components includes a wide range of materials and process techniques. During one such additive manufacturing process, a powder material may be deposited onto a working surface. Many layers may be formed on top of one another in a sequence to achieve a net shape or a partial net shape component.
  • a heat source such as a laser beam, is directed onto the working surface. The deposited powder material is melted by the laser beam and fused to the working surface.
  • a turbine airfoil is one example of a superalloy component experiencing damage and degradation during operation of the gas turbine engine.
  • the turbine airfoil may be the airfoil of a rotating blade or a stationary vane in a gas turbine engine.
  • the tip of the turbine airfoil is particularly vulnerable to damage and degradation with the result that most of the damage and degradation occurs in the tip.
  • the tip may be defined as 5 to 10% of its length extending radially inward from the end of the airfoil opposite the root which couples the turbine airfoil to a disc of the turbine engine.
  • FIG. 1 illustrates a system 100 for additively manufacturing or repairing a tip (t) of a superalloy component 110 utilizing a braze material 130.
  • the superalloy component 110 depicted in the disclosure is a turbine airfoil such as a turbine blade or vane, however, one skilled in the art would appreciate that the superalloy component may be any superalloy component having a tip.
  • the system 100 may include a heating system operably configured to produce heat up to and beyond a grain boundary temperature of the base metal of the tip (t) of the superalloy component 110.
  • Fig. 2 illustrates an embodiment of a heating system 160 utilized to heat the tip (t) of a turbine airfoil 110 to a predetermined temperature.
  • an induction coil is utilized as the heating source 160.
  • the induction coil 160 may surround the tip (t) of the airfoil 110 as shown.
  • the system 100 may also include a laser energy source 120 for emitting a laser energy 125.
  • the laser energy 125 may be directed towards the braze material 130 so that the braze material 130 melts and additively forms a deposited layer 150 on the tip (t).
  • the braze material 130 may be in the form of a sintered weld rod 130, as illustrated in Fig. 2, or a wire feed.
  • the sintered weld rod 130 or wire feed may extend toward the tip (t) so that an end contacts the tip (t) of the superalloy component 110.
  • the laser energy source 120 may direct the laser energy 125 towards the end of the sintered weld rod 130 melting the sintered weld rod 130 or wire feed while in contact with the tip (t) forming the deposited layer 150 of additive material.
  • the method of creating a sintered weld rod 130 as well as its composition may be found in co-pending international (PCT) patent application number PCT/US18/19077 which is incorporated by reference herein.
  • the sintered weld rod 130 may comprise a mixture of braze alloy powder and base metal powder, the base metal powder corresponding to the composition of the tip (t) of the superalloy component.
  • the use of the sintered weld rod 130 or wire feed allows better process control than conventional powder feeding into a laser weld pool. Additionally, a waste of the powder which may occur during a laser additive manufacturing process is eliminated.
  • the system 100 may include a means for sub-cooling 140 the deposited layer 150.
  • sub-cooling may be defined as a cooling temperature range resulting in a cooling/freezing effect of the deposited layer after its deposit onto the base material of the tip (t).
  • the sub-cooling temperatures may lie in a range between -l00-300°C.
  • the sub-cooling means 140 may comprise a stream of liquid nitrogen directed towards the deposited layer 150, as shown in Fig. 1.
  • the sub-cooling may be accomplished by immersing the tip (t) into dry ice.
  • the present inventors have recognized that sub- cooling the deposited layer 150 before, during, and/or after the layer 150 is deposited absorbs the heat quickly from the molten braze suppressing the formation of deleterious compounds that may cause cracking in the deposited layer 150.
  • a method of additively manufacturing or repairing a superalloy component 110 is also provided.
  • the tip (t) Prior to laser braze repairing the tip (t) of the superalloy component 110, the tip (t) undergoes at least a double solution pre-heat treatment at progressively higher temperatures in order to raise the grain boundary melting temperature and dissolve deleterious phases in the tip (t).
  • the at least double solution pre-heat treatment eliminates approximately 99% of the eutectic gamma prime phases.
  • a first heat treatment may begin and includes heating the tip (t) to a first temperature for a specified or predetermined time period.
  • the first temperature may be the base metal solution treatment temperature plus l0°C.
  • the first temperature may be l245°C when the base metal alloy is CM 247.
  • the first temperature should be high enough to reduce or dissolve a portion, for example around 80%, of the deleterious phases of the component material that may cause cracking during welding.
  • the first temperature should also be low enough to allow for subsequent heat treatments at temperatures higher than the first temperature.
  • the first temperature should be held for a first time period.
  • the first time period may be up to approximately 2 hours or until most of the eutectic gamma prime phases are dissolved.
  • the tip (t) is cooled down to ambient temperature. The cooling may be performed under argon gas or other cooling means known in the art.
  • the method may further include a second heat treatment by heating the tip (t) to a second temperature for a second time period.
  • the second temperature may be a temperature below the grain boundary melt temperature but above the first temperature.
  • the second temperature should be high enough to further dissolve the remaining deleterious phases in the tip (t). For example, with the second heat treatment, 50% of the remaining phases may be dissolved such that 90% of the deleterious phases are dissolved after the second heat treatment.
  • the second temperature may be l0°C above the first heat treatment temperature. For example, for the base metal alloy CM 247, the second temperature may be l255°C. Once the second temperature has been attained, it should be held for a second time period.
  • the second time period may be up to approximately 2 hours or until a majority of the remaining eutectic gamma prime phases are dissolved.
  • the tip (t) is cooled down to ambient temperature. Again, the cooling may be performed under argon gas.
  • the tip (t) of the component 110 may be ready for depositing additive material or laser braze repair.
  • the tip may undergo a third heat treatment to further dissolve any remaining deleterious phases in the material of the tip (t). For example, with the third heat treatment another 50% or more of the remaining eutectic gamma prime phases may be dissolved.
  • the third temperature may be at least 5°C above the last heat treatment. Once the third temperature has been attained, it should be held for a third time period. The third time period may be up to approximately 2 hours or until a majority of the remaining eutectic gamma prime phases are dissolved.
  • the tip (t) is cooled down to ambient temperature. Again, the cooling may be performed under argon gas.
  • the tip (t) is cooled down to ambient temperature. Again, the cooling may be performed under argon gas.
  • the braze repair or additive manufacture of the tip (t) may be illustrated in
  • a layer of braze material 130 is deposited on an end surface of the tip (t) at a temperature less than the melting temperature of the base material of the tip (t).
  • the braze repair utilizes a laser energy source 120 to melt a braze material while in contact with the tip (t) so that when cooled the melted braze material forms the deposited layer 150.
  • a sintered weld rod 130 may comprise the braze material.
  • a wire feed comprises the braze material. In this step, it should be appreciated that the rod 130 or wire feed may be attached to a nozzle or other tool in order to be kept in contact with the tip (t) or the wire feed may be fed through a laser source tool.
  • the deposited layer 150 is sub-cooled.
  • the deposited layer 150 may be sub-zero cooled as the sub-cooling may be accomplished with materials having below freezing temperatures.
  • a stream of liquid nitrogen, as illustrated, or other liquid medium capable of cooling the deposited layer to a desired temperature range is used so that any heat from the deposited molten material may be released or removed.
  • the deposited material may be cooled down to a temperature less than -50°C.
  • the sub- cooling is accomplished by immersing the tip in dry ice. Dry ice may be beneficial as it does not introduce any moisture into the process.
  • the sub-cooling of the deposited layer 150 may suppress the formation of the deleterious phases in the tip (t) that cause cracking.
  • a successive layer or a plurality of successive layers may be deposited or built on top of the deposited layer 150 after the sub-cooling.
  • a plurality of layers may be additively built on the tip (t) of the component 110 so that an eroded portion of the tip (t) may be rebuilt, for example.
  • the method may include preparing the tip (t) for laser processing prior to the at least double solution heat treatment.
  • Preparing the tip for laser processing may include, e.g., removing the component (damaged or otherwise) from an industrial machine, e.g., a turbo machine engine.
  • the preparing steps may also include removing any damaged portions from the tip.
  • the damaged portions may be removed by grinding, milling, or other means for removing damaged portions of a superalloy component known in the art.
  • the component may be placed or removably secured to, e.g., a laser deposition fixture (not shown) or other type of securing means in, e.g., a chamber or other defined work area, for build-up and/or repair laser process with the embodiment of the sintered weld rod.
  • a laser deposition fixture not shown
  • other type of securing means in, e.g., a chamber or other defined work area, for build-up and/or repair laser process with the embodiment of the sintered weld rod.
  • the disclosed method of additively manufacturing or laser braze repairing a superalloy component allows tip repair of turbine blades and vanes without recrystallization since only the tip of the blade or vane is exposed to high heat with the result that the properties at the tip will be different than the properties of the remaining portions of the blade or vane.
  • the method accomplishes this though a super solution heat treatment to only the area of build-up and not the remaining area of the component.
  • Laser braze repair lowers the deposition temperature by utilizing a braze material instead of base metal powder.
  • the method utilizes sub-cooling of the deposited layer as soon as the laser brazing is finished to minimize the grain boundary segregation and minimize the size of gamma prime phases forming during cooling on the additive layer and the heat affected zone. Utilizing this method and/or system, a deposited layer on a tip of a turbine airfoil cools without cracking or with minimal cracking to the newly deposited layer.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Thermal Sciences (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Laser Beam Processing (AREA)
  • Welding Or Cutting Using Electron Beams (AREA)

Abstract

L'invention concerne un procédé de fabrication ou de réparation additive d'un élément en superalliage utilisant au moins un traitement thermique en double solution et un sous-refroidissement. Ledit au moins un traitement thermique en double solution consiste à chauffer la pointe d'un élément en superalliage à une première température pendant une première durée puis permettre à la pointe de refroidir jusqu'à la température ambiante, puis chauffer la pointe jusqu'à une seconde température pendant une seconde durée, puis permettre à la pointe de refroidir jusqu'à la température ambiante. Un processus de fabrication additive ou de réparation par brasage laser de la pointe commence par le dépôt d'une couche de matériau de brasage sur une surface d'extrémité de la pointe à une température inférieure à la température de fusion de la composition du matériau de base de l'élément. Le sous-refroidissement de la couche déposée est réalisé directement après la réparation par brasage laser. L'invention concerne également un système de fabrication ou de réparation additive.
PCT/US2018/022532 2018-03-15 2018-03-15 Fabrication additive à fil de brasage laser d'un élément d'aube de turbine en super-solution avec refroidissement au-dessous de zéro Ceased WO2019177607A1 (fr)

Priority Applications (1)

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PCT/US2018/022532 WO2019177607A1 (fr) 2018-03-15 2018-03-15 Fabrication additive à fil de brasage laser d'un élément d'aube de turbine en super-solution avec refroidissement au-dessous de zéro

Applications Claiming Priority (1)

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PCT/US2018/022532 WO2019177607A1 (fr) 2018-03-15 2018-03-15 Fabrication additive à fil de brasage laser d'un élément d'aube de turbine en super-solution avec refroidissement au-dessous de zéro

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WO2022063085A1 (fr) * 2020-09-23 2022-03-31 International Business Machines Corporation Fil robotique autonome pour réparer des structures
CN115889803A (zh) * 2022-11-29 2023-04-04 沈阳航空航天大学 一种电弧增材制造原位固溶方法及系统
CN116511522A (zh) * 2023-04-25 2023-08-01 华中科技大学 一种金属表面激光定向能沉积增材制造方法
CN116568455A (zh) * 2020-12-10 2023-08-08 赛峰集团 包括凹槽状顶端下方的腔体的高压涡轮轮叶
EP4414101A1 (fr) * 2023-02-10 2024-08-14 Pratt & Whitney Canada Corp. Révision adaptative à l'aide d'un ensemble de données unique de balayage ct
EP4414102A1 (fr) * 2023-02-10 2024-08-14 Pratt & Whitney Canada Corp. Révision adaptative utilisant un ensemble de données unique à lumière structurée
EP4424440A1 (fr) * 2023-03-02 2024-09-04 Pratt & Whitney Canada Corp. Révision adaptative utilisant plusieurs procédés de balayage
US12251757B2 (en) 2022-09-09 2025-03-18 Pratt & Whitney Canada Corp. Adaptively depositing braze material(s) using CT scan data
US12296400B2 (en) 2022-09-09 2025-05-13 Pratt & Whitney Canada Corp. Additively depositing multiple braze materials
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US12551974B2 (en) 2022-09-09 2026-02-17 Pratt & Whitney Canada Corp. Adaptive component overhaul using structured light scan data
EP4721912A1 (fr) * 2024-09-26 2026-04-08 RTX Corporation Appareil et procédés associés pour réparer des pièces de machine à l'aide d'un système de préchauffage hybride
US12617018B2 (en) 2023-03-03 2026-05-05 Pratt & Whitney Canada Corp. Adaptive overhaul with two braze material and structured light scans

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Cited By (21)

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US11396063B2 (en) 2020-03-23 2022-07-26 Rosemount Aerospace Inc. Systems and methods for in process heating for direct energy deposition applications
EP3885065A1 (fr) * 2020-03-23 2021-09-29 Rosemount Aerospace Inc. Systèmes et procédés de chauffage en cours de processus pour des applications de dépôt d'énergie directe
US11759875B2 (en) 2020-09-23 2023-09-19 International Business Machines Corporation Autonomous robotic thread for repairing structures
WO2022063085A1 (fr) * 2020-09-23 2022-03-31 International Business Machines Corporation Fil robotique autonome pour réparer des structures
GB2613985A (en) * 2020-09-23 2023-06-21 Ibm Autonomous robotic thread for repairing structures
GB2613985B (en) * 2020-09-23 2024-03-27 Ibm Autonomous robotic thread for repairing structures
CN116568455A (zh) * 2020-12-10 2023-08-08 赛峰集团 包括凹槽状顶端下方的腔体的高压涡轮轮叶
US12370603B2 (en) 2022-09-09 2025-07-29 Pratt & Whitney Canada Corp. Adaptive manufacturing using CT scan data
US12551974B2 (en) 2022-09-09 2026-02-17 Pratt & Whitney Canada Corp. Adaptive component overhaul using structured light scan data
US12251757B2 (en) 2022-09-09 2025-03-18 Pratt & Whitney Canada Corp. Adaptively depositing braze material(s) using CT scan data
US12358232B2 (en) 2022-09-09 2025-07-15 Pratt & Whitney Canada Corp. Adaptive manufacturing using structured light data
US12296400B2 (en) 2022-09-09 2025-05-13 Pratt & Whitney Canada Corp. Additively depositing multiple braze materials
CN115889803A (zh) * 2022-11-29 2023-04-04 沈阳航空航天大学 一种电弧增材制造原位固溶方法及系统
EP4414102A1 (fr) * 2023-02-10 2024-08-14 Pratt & Whitney Canada Corp. Révision adaptative utilisant un ensemble de données unique à lumière structurée
EP4414101A1 (fr) * 2023-02-10 2024-08-14 Pratt & Whitney Canada Corp. Révision adaptative à l'aide d'un ensemble de données unique de balayage ct
US12115598B2 (en) 2023-03-02 2024-10-15 Pratt & Whitney Canada Corp. Adaptive overhaul using plural scanning methods
EP4424440A1 (fr) * 2023-03-02 2024-09-04 Pratt & Whitney Canada Corp. Révision adaptative utilisant plusieurs procédés de balayage
US12617018B2 (en) 2023-03-03 2026-05-05 Pratt & Whitney Canada Corp. Adaptive overhaul with two braze material and structured light scans
CN116511522A (zh) * 2023-04-25 2023-08-01 华中科技大学 一种金属表面激光定向能沉积增材制造方法
CN116511522B (zh) * 2023-04-25 2026-04-03 华中科技大学 一种金属表面激光定向能沉积增材制造方法
EP4721912A1 (fr) * 2024-09-26 2026-04-08 RTX Corporation Appareil et procédés associés pour réparer des pièces de machine à l'aide d'un système de préchauffage hybride

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