CA2830998C - Method for repairing an aluminium alloy component - Google Patents
Method for repairing an aluminium alloy component Download PDFInfo
- Publication number
- CA2830998C CA2830998C CA2830998A CA2830998A CA2830998C CA 2830998 C CA2830998 C CA 2830998C CA 2830998 A CA2830998 A CA 2830998A CA 2830998 A CA2830998 A CA 2830998A CA 2830998 C CA2830998 C CA 2830998C
- Authority
- CA
- Canada
- Prior art keywords
- repaired
- component
- precipitation
- thermal treatment
- hours
- 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.)
- Expired - Fee Related
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C26/00—Coating not provided for in groups C23C2/00 - C23C24/00
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
Abstract
The invention refers to a method for the repair of an aluminium alloy component, in particular a precipitation- hardened aluminium alloy component, comprising the steps of: a) depositing by cold spray on said component to be repaired a portion of supplied material, thus obtaining a partially repaired component; b) subjecting said partially repaired component to a thermal treatment, thus obtaining a repaired component, the conditions of performance of said thermal treatment being selected according to the composition and dimensional tolerances of said component.
Description
"METFIOD FOR REPAIRING AN ALUMINIUM ALLOY COMPONENT"
TECHNICAL FIELD
The present invention concerns a method for repairing an aluminium alloy component, in particular a precipitation-hardened aluminium alloy component.
BACKGROUND ART
As is known, aeronautical components, in general, are subjected during use to high levels of mechanical stress and must therefore have specific mechanical properties, in particular in terms of mechanical resistance at high temperature, hardness and wear resistance.
In particular, this need is felt for components such as accessory or power transmission housings for aeronautical and helicopter engines. Said components are typically made of precipitation-hardened lightweight aluminium alloys.
Frequently, said components need repairs. This can occur in the various manufacturing phases of new components, for example at the level of production of the castings, semi-finished products or after a machining phase, for dimensional reasons or due to local damage resulting from handling or transport, or due to metallurgical defects such as porosity, cracks or inclusions. Moreover, finished components frequently have to be repaired after a period of operation due to problems of wear, corrosion, undesired impacts or other.
Traditionally, repair of aluminium alloy components is carried out using various technologies including: repair by deposit of weld material (TIG welding, laser cladding, etc.); application of high resistance resins; interference fit (for recovery of oversized internal diameters by means of bushing); depositing techniques by thermal spraying.
TECHNICAL FIELD
The present invention concerns a method for repairing an aluminium alloy component, in particular a precipitation-hardened aluminium alloy component.
BACKGROUND ART
As is known, aeronautical components, in general, are subjected during use to high levels of mechanical stress and must therefore have specific mechanical properties, in particular in terms of mechanical resistance at high temperature, hardness and wear resistance.
In particular, this need is felt for components such as accessory or power transmission housings for aeronautical and helicopter engines. Said components are typically made of precipitation-hardened lightweight aluminium alloys.
Frequently, said components need repairs. This can occur in the various manufacturing phases of new components, for example at the level of production of the castings, semi-finished products or after a machining phase, for dimensional reasons or due to local damage resulting from handling or transport, or due to metallurgical defects such as porosity, cracks or inclusions. Moreover, finished components frequently have to be repaired after a period of operation due to problems of wear, corrosion, undesired impacts or other.
Traditionally, repair of aluminium alloy components is carried out using various technologies including: repair by deposit of weld material (TIG welding, laser cladding, etc.); application of high resistance resins; interference fit (for recovery of oversized internal diameters by means of bushing); depositing techniques by thermal spraying.
2 Said technologies have various drawbacks,. as will be illustrated below.
Repair techniques based on welding are widely used for the repair of rough components prior to heat treatment. They have the undoubted advantage of producing a metallurgical link with the material of the substrate, but they are difficult to apply to the repair of components that have already been machined, due to the deformations produced by the welding.
Furthermore, in particular for precipitation-hardened aluminium alloys, the weld material has a very different microstructure and significantly inferior mechanical properties with respect to the substrate.
The repair techniques by application of high resistance polymeric resins have limited applicability due to the evident =dissimilarity between the metallic base material and the supplied material, which consists substantially of an organic resin. The high polymerisation temperatures of some epoxy type resins, which can be in the order of 200 C, moreover, can cause an undesirable deterioration in the mechanical characteristics of some precipitation-hardened lightweight alloys.
The repair techniques based on interference fit are usually used for recovering worn or oversized internal diameters, but this type of application is evidently limited by geometric and structural factors.
Repair of components made of aluminium or relative alloys by means of thermal spraying techniques entails depositing of supplied material in which the particles of the material to be deposited are brought to a high temperature which causes them =
to melt. This technology consequently has the disadvantage, as regards the depositing of aluminium powder, of favouring oxidisation of the melted particles in contact with the
Repair techniques based on welding are widely used for the repair of rough components prior to heat treatment. They have the undoubted advantage of producing a metallurgical link with the material of the substrate, but they are difficult to apply to the repair of components that have already been machined, due to the deformations produced by the welding.
Furthermore, in particular for precipitation-hardened aluminium alloys, the weld material has a very different microstructure and significantly inferior mechanical properties with respect to the substrate.
The repair techniques by application of high resistance polymeric resins have limited applicability due to the evident =dissimilarity between the metallic base material and the supplied material, which consists substantially of an organic resin. The high polymerisation temperatures of some epoxy type resins, which can be in the order of 200 C, moreover, can cause an undesirable deterioration in the mechanical characteristics of some precipitation-hardened lightweight alloys.
The repair techniques based on interference fit are usually used for recovering worn or oversized internal diameters, but this type of application is evidently limited by geometric and structural factors.
Repair of components made of aluminium or relative alloys by means of thermal spraying techniques entails depositing of supplied material in which the particles of the material to be deposited are brought to a high temperature which causes them =
to melt. This technology consequently has the disadvantage, as regards the depositing of aluminium powder, of favouring oxidisation of the melted particles in contact with the
3 atmospheric oxygen.
Furthermore, the mechanical properties of the portion of supplied material are decidedly inferior to those of the substrate, and also the quality of the relative adhesion is generally unsatisfactory.
To remedy this drawback, thermal spraying for repair of aluminium alloys is often perfoimed by depositing materials different from the base material. Bronze powders or Ni-Al alloys are often used. However, the application of materials different from the base material entails other problems connected with the different behaviour of dissimilar materials during the component manufacturing completion processes (for example in the case of application of the anode oxidisation process of the aluminium component) or during operation (for example due to effects of accelerated galvanic corrosion, differential thermal expansion coefficients, etc.).
A further disadvantage of the repair techniques by traditional thermal spraying processes (plasma spray, HVOF, thermo-spray, D-gun, etc.) derives from the fact that the substrate temperature must be very carefully monitored to avoid excessive temperatures being reached with consequent possible deterioration of the mechanical properties. It is known, in fact, that aluminium alloys, in particular those hardened by precipitation of hardening phases, can rapidly lose their characteristics of tensile strength and yield strength following heating to temperatures higher than the precipitation temperatures.
The need is therefore felt in the sector to provide a method for the repair of aluminium alloy components, in particular precipitation-hardened aluminium alloy components, which overcomes at least one of the drawbacks described previously.
=
PCT/1113201 2/1)51434
Furthermore, the mechanical properties of the portion of supplied material are decidedly inferior to those of the substrate, and also the quality of the relative adhesion is generally unsatisfactory.
To remedy this drawback, thermal spraying for repair of aluminium alloys is often perfoimed by depositing materials different from the base material. Bronze powders or Ni-Al alloys are often used. However, the application of materials different from the base material entails other problems connected with the different behaviour of dissimilar materials during the component manufacturing completion processes (for example in the case of application of the anode oxidisation process of the aluminium component) or during operation (for example due to effects of accelerated galvanic corrosion, differential thermal expansion coefficients, etc.).
A further disadvantage of the repair techniques by traditional thermal spraying processes (plasma spray, HVOF, thermo-spray, D-gun, etc.) derives from the fact that the substrate temperature must be very carefully monitored to avoid excessive temperatures being reached with consequent possible deterioration of the mechanical properties. It is known, in fact, that aluminium alloys, in particular those hardened by precipitation of hardening phases, can rapidly lose their characteristics of tensile strength and yield strength following heating to temperatures higher than the precipitation temperatures.
The need is therefore felt in the sector to provide a method for the repair of aluminium alloy components, in particular precipitation-hardened aluminium alloy components, which overcomes at least one of the drawbacks described previously.
=
PCT/1113201 2/1)51434
4 More specifically the need is felt, especially in the aeronautical sector, to provide a method for the repair of aluminium alloy components which gives the repaired components mechanical characteristics that meet the requirements of the particular conditions of use, with particular reference to the uniformity of the properties between the material forming the support (or the component to be repaired) and the portion of supplied material, and their relative adhesion.
Furthermore, the need is felt in the sector to provide a method for the repair of aluminium alloy components, in particular precipitation-hardened aluminium alloy components, which requires low plant investment and reduced management and maintenance costs and which can guarantee high productivity.
DISCLOSURE OF INVENTION
The object of the present invention is therefore to provide a method for the repair of aluminium alloy components, in particular precipitation-hardened aluminium alloy components, said method meeting simply and economically at least one of the above-mentioned needs.
4a According to one aspect, there is provided a method for repairing a precipitation hardened aluminium alloy component comprising the steps of:
a) cold spray depositing on the component to be repaired a portion of supplied material having a composition identical to that of the component to be repaired, thus obtaining a partially repaired component;
b) subjecting the partially repaired component to a the/mal treatment, thus obtaining a repaired component, the conditions for performing the thermal treatment being selected as a function of the composition and of dimension tolerances of the component, characterised in that the step b) of thermal treatment comprises:
c) a first step of solubilisation followed by cooling in water; and d) a second step, following the first step c), of precipitation.
BEST MODE FOR CARRYING OUT THE INVENTION
For a better understanding of the present invention, a preferred embodiment thereof is described below, purely by way of non-limiting example.
Advantageously, an aluminium alloy component and, in particular, a precipitation-hardened aluminium alloy component, is repaired by depositing by cold spray a portion of supplied material on the component to be repaired, thus 35 obtaining a partially repaired component.
In the context of the invention, "component to be repaired"
indicates an aluminium alloy component which requires repair, regardless of the machining state of said component.
Furthermore, the need is felt in the sector to provide a method for the repair of aluminium alloy components, in particular precipitation-hardened aluminium alloy components, which requires low plant investment and reduced management and maintenance costs and which can guarantee high productivity.
DISCLOSURE OF INVENTION
The object of the present invention is therefore to provide a method for the repair of aluminium alloy components, in particular precipitation-hardened aluminium alloy components, said method meeting simply and economically at least one of the above-mentioned needs.
4a According to one aspect, there is provided a method for repairing a precipitation hardened aluminium alloy component comprising the steps of:
a) cold spray depositing on the component to be repaired a portion of supplied material having a composition identical to that of the component to be repaired, thus obtaining a partially repaired component;
b) subjecting the partially repaired component to a the/mal treatment, thus obtaining a repaired component, the conditions for performing the thermal treatment being selected as a function of the composition and of dimension tolerances of the component, characterised in that the step b) of thermal treatment comprises:
c) a first step of solubilisation followed by cooling in water; and d) a second step, following the first step c), of precipitation.
BEST MODE FOR CARRYING OUT THE INVENTION
For a better understanding of the present invention, a preferred embodiment thereof is described below, purely by way of non-limiting example.
Advantageously, an aluminium alloy component and, in particular, a precipitation-hardened aluminium alloy component, is repaired by depositing by cold spray a portion of supplied material on the component to be repaired, thus 35 obtaining a partially repaired component.
In the context of the invention, "component to be repaired"
indicates an aluminium alloy component which requires repair, regardless of the machining state of said component.
5 "Regardless of the machining state of said component"
indicates that the component to be repaired can be, with reference to the relative manufacturing process: in the rough state; in the state of a semi-finished product; finished; or even a finished component which has already been operating and which requires repair to remedy damage sustained during operation in situ.
The "component to be repaired" constitutes the substrate of the cold spray depositing phase, which will be described in greater detail below.
Following the step of depositing the portion of supplied material on the component to be repaired, a "partially repaired component" is obtained.
Cold spray depositing is a relatively recent technique which entails the depositing of metallic materials in the form of powder. Unlike the thermal spraying processes, however, in cold spray depositing the supplied material remains in the solid state without ever reaching the melting conditions.
Typically, according to this technique, a metallic powder or a mixture of metallic powders having a pre-defined composition is injected via a nozzle and applied to a substrate, undergoing acceleration in the non-melted state, at speeds in the order of 300 4 1,200 m/s by means of a flow of carrier gas which crosses the nozzle. Impacting with the substrate with sufficient kinetic energy, the particles of the powder locally deform the substrate and are themselves deformed.
In the context of the invention, the component to be repaired
indicates that the component to be repaired can be, with reference to the relative manufacturing process: in the rough state; in the state of a semi-finished product; finished; or even a finished component which has already been operating and which requires repair to remedy damage sustained during operation in situ.
The "component to be repaired" constitutes the substrate of the cold spray depositing phase, which will be described in greater detail below.
Following the step of depositing the portion of supplied material on the component to be repaired, a "partially repaired component" is obtained.
Cold spray depositing is a relatively recent technique which entails the depositing of metallic materials in the form of powder. Unlike the thermal spraying processes, however, in cold spray depositing the supplied material remains in the solid state without ever reaching the melting conditions.
Typically, according to this technique, a metallic powder or a mixture of metallic powders having a pre-defined composition is injected via a nozzle and applied to a substrate, undergoing acceleration in the non-melted state, at speeds in the order of 300 4 1,200 m/s by means of a flow of carrier gas which crosses the nozzle. Impacting with the substrate with sufficient kinetic energy, the particles of the powder locally deform the substrate and are themselves deformed.
In the context of the invention, the component to be repaired
6 forms the "substrate" on which the metallic powder is deposited constituting a "portion of supplied material".
Preferably, the metallic powder or mixture of metallic powders used for depositing the portion of supplied material has a composition substantially identical to that .of the substrate (i.e. :the component to be repaired). The use of supplied material with composition substantially identical to that of the substrate has the advantage of minimising the differences in behaviour between the substrate and the supplied material, restoring as far as possible the conditions of the repaired component with respect to the new component.
For physical and chemical-physical reasons, the technique. of cold spray depositing favours the formation of a portion of supplied material which is compact and securely adhering to the substrate. In particular, this advantageous result is promoted . by the reciprocal interpenetration of supplied material and substrate and the breakage, at the moment of impact, of the fine surface layers of oxide which, in practice, are always present in the materials exposed to the external atmosphere.
This aspect is particularly advantageous in the case of repair of components damaged during operation, or when they have been exposed for a prolonged period to aggressive atmospheric conditions.
Typically, in the cold spray depositing technique, a compressed gas flow at a pressure of approximately 5+50 bars is used. This gas flow envelops the particles of metallic powder and entrains them, expelling them through the nozzle at high speed. Optionally, at least a part of the gas flow is heated before arriving at the application nozzle.
Preferably, a monatomic inert gas such as helium is used as
Preferably, the metallic powder or mixture of metallic powders used for depositing the portion of supplied material has a composition substantially identical to that .of the substrate (i.e. :the component to be repaired). The use of supplied material with composition substantially identical to that of the substrate has the advantage of minimising the differences in behaviour between the substrate and the supplied material, restoring as far as possible the conditions of the repaired component with respect to the new component.
For physical and chemical-physical reasons, the technique. of cold spray depositing favours the formation of a portion of supplied material which is compact and securely adhering to the substrate. In particular, this advantageous result is promoted . by the reciprocal interpenetration of supplied material and substrate and the breakage, at the moment of impact, of the fine surface layers of oxide which, in practice, are always present in the materials exposed to the external atmosphere.
This aspect is particularly advantageous in the case of repair of components damaged during operation, or when they have been exposed for a prolonged period to aggressive atmospheric conditions.
Typically, in the cold spray depositing technique, a compressed gas flow at a pressure of approximately 5+50 bars is used. This gas flow envelops the particles of metallic powder and entrains them, expelling them through the nozzle at high speed. Optionally, at least a part of the gas flow is heated before arriving at the application nozzle.
Preferably, a monatomic inert gas such as helium is used as
7 PCT/IB2012/051434 the carrier gas. Helium has the twin advantage of allowing, as a monatomic gas, acceleration of the particles at the highest speeds and simultaneously, due to its inertia, excluding the possibility of oxidisation of the metallic powder. However, since the contact times between the components of the mixture of metallic powders and the carrier gas are very limited, it is also possible to use cheaper carrier gases, such as nitrogen or air, although, at the same pressure, the speeds that can be reached by the particles are inferior to those that can be reached with helium.
The depositing temperature is typically the lowest possible, compatibly with the need to obtain a minimum level of deformation of the sprayed powder particles.
The mean dimension of the metallic particles forming the powder to be deposited can be advantageously chosen in the range between 1 and 200 m.
This technique therefore favours by nature the formation of a portion of supplied material having a low porosity level and good- adhesion characteristics vis-a-vis the material constituting the support.
In the case of aluminium alloy components and, more specifically, precipitation-hardened aluminium alloy components, the portion of supplied material deposited by cold spray typically has a high fragility and high internal tensions which are not wholly satisfactory in view of the use in the aeronautical sector.
In general, a significant lack of uniformity in terms of mechanical properties and microstructural characteristics is typically found between the substrate and the portion of supplied material deposited by cold spray. This lack of uniformity is undesirable in view of the intended use of the
The depositing temperature is typically the lowest possible, compatibly with the need to obtain a minimum level of deformation of the sprayed powder particles.
The mean dimension of the metallic particles forming the powder to be deposited can be advantageously chosen in the range between 1 and 200 m.
This technique therefore favours by nature the formation of a portion of supplied material having a low porosity level and good- adhesion characteristics vis-a-vis the material constituting the support.
In the case of aluminium alloy components and, more specifically, precipitation-hardened aluminium alloy components, the portion of supplied material deposited by cold spray typically has a high fragility and high internal tensions which are not wholly satisfactory in view of the use in the aeronautical sector.
In general, a significant lack of uniformity in terms of mechanical properties and microstructural characteristics is typically found between the substrate and the portion of supplied material deposited by cold spray. This lack of uniformity is undesirable in view of the intended use of the
8 components.
Furthermore, the adhesion quality between the portion of supplied material deposited and the substrate, although generally better than other depositing techniques by thermal spraying, is generally limited.
Advantageously, according to the invention, the method for the repair of aluminium alloy components furthermore comprises the step of subjecting the partially repaired component obtained from the cold spray depositing phase to a thermal treatment, thus obtaining a repaired component.
Said thermal treatment has the purpose of improving the mechanical characteristics of the portion of supplied material, with the objective of reducing the lack of uniformity between portion of supplied material and substrate.
Furthermore, said thermal treatment is conceived to improve the quality of the adhesion between the portion of supplied material and the substrate.
Advantageously, according to the invention, a repaired component is subjected to a specific thermal treatment, the performance conditions of which have been selected according to the composition and dimensional tolerances of said component to be repaired.
Furthermore, it will also be possible to take account of the final use of the component, once repaired.
If the component to be repaired has sufficiently broad dimensional tolerances to allow for any deformations produced by the thermal treatment, the partially repaired component is advantageously subjected to the specific thermal treatment of the alloy, comprising:
- a first step of solubilisation followed by rabid cooling;
and
Furthermore, the adhesion quality between the portion of supplied material deposited and the substrate, although generally better than other depositing techniques by thermal spraying, is generally limited.
Advantageously, according to the invention, the method for the repair of aluminium alloy components furthermore comprises the step of subjecting the partially repaired component obtained from the cold spray depositing phase to a thermal treatment, thus obtaining a repaired component.
Said thermal treatment has the purpose of improving the mechanical characteristics of the portion of supplied material, with the objective of reducing the lack of uniformity between portion of supplied material and substrate.
Furthermore, said thermal treatment is conceived to improve the quality of the adhesion between the portion of supplied material and the substrate.
Advantageously, according to the invention, a repaired component is subjected to a specific thermal treatment, the performance conditions of which have been selected according to the composition and dimensional tolerances of said component to be repaired.
Furthermore, it will also be possible to take account of the final use of the component, once repaired.
If the component to be repaired has sufficiently broad dimensional tolerances to allow for any deformations produced by the thermal treatment, the partially repaired component is advantageously subjected to the specific thermal treatment of the alloy, comprising:
- a first step of solubilisation followed by rabid cooling;
and
9 - a second step, following the first one, of precipitation.
If the component to be repaired is obtained from Al-Si alloys, type 355, 356 or 357, the first phase of solubilisation is preferably performed at a temperature from 500 to 580 C, more preferably from 530 C to 550 C, for a time in the range between 6 and 20 hours, while the precipitation phase is preferably performed at a temperature from 100 to 300 C, more preferably from 150 C to 230 C, for a time in the range between 3 and 12 hours.
If the component to be repaired is obtained from Al-Cu alloys, type 2014, 2618, 2024, the first step of solubilisation is preferably performed at a temperature from 400 to 600 C, more preferably from 460 C to 535 C, for a time in the range between 1 and 3 hours, while the step of precipitation is preferably performed at a temperature from 150 to 250 C, more preferably from 160 C to 200 C, for a time in the range between 8 and 20 hours.
Some examples are given below of the advantages that can be obtained with application of the complete thermal treatment of solubilisation and ageing on test pieces made of 357 aluminium-silicon alloy repaired by means of cold spray using 357 aluminium-silicon alloy powder as the supplied material:
Example la: Repair of rough components in 357 aluminium-silicon alloy already subjected to complete thermal treatment of solubilisation and precipitation (ageing).
The mechanical strength of the 357 aluminium-silicon alloy with complete thermal treatment, measured on cylindrical test pieces with diameter 9.0 mm according to ASTM B557, is on average 307 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove of depth such as to reduce the resistant area to 49,6- of the original area. The mean mechanical resistance measured on these test pieces was 179 MPa.
The test pieces with simulated defect were repaired by means 5 of cold spray by depositing a layer of 357 aluminium alloy powder of thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the mechanical resistance
If the component to be repaired is obtained from Al-Si alloys, type 355, 356 or 357, the first phase of solubilisation is preferably performed at a temperature from 500 to 580 C, more preferably from 530 C to 550 C, for a time in the range between 6 and 20 hours, while the precipitation phase is preferably performed at a temperature from 100 to 300 C, more preferably from 150 C to 230 C, for a time in the range between 3 and 12 hours.
If the component to be repaired is obtained from Al-Cu alloys, type 2014, 2618, 2024, the first step of solubilisation is preferably performed at a temperature from 400 to 600 C, more preferably from 460 C to 535 C, for a time in the range between 1 and 3 hours, while the step of precipitation is preferably performed at a temperature from 150 to 250 C, more preferably from 160 C to 200 C, for a time in the range between 8 and 20 hours.
Some examples are given below of the advantages that can be obtained with application of the complete thermal treatment of solubilisation and ageing on test pieces made of 357 aluminium-silicon alloy repaired by means of cold spray using 357 aluminium-silicon alloy powder as the supplied material:
Example la: Repair of rough components in 357 aluminium-silicon alloy already subjected to complete thermal treatment of solubilisation and precipitation (ageing).
The mechanical strength of the 357 aluminium-silicon alloy with complete thermal treatment, measured on cylindrical test pieces with diameter 9.0 mm according to ASTM B557, is on average 307 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove of depth such as to reduce the resistant area to 49,6- of the original area. The mean mechanical resistance measured on these test pieces was 179 MPa.
The test pieces with simulated defect were repaired by means 5 of cold spray by depositing a layer of 357 aluminium alloy powder of thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the mechanical resistance
10 measured on the repaired test pieces was on average 226 MPa.
Analogous test pieces repaired by cold spray and subjected, after repair, to thermal solubilisation treatment at 540 C for 17.5 hours with cooling in water, followed by thermal treatment of precipitation (ageing) at 200 C for 7 hours, showed a mean mechanical resistance of 250 MPa, with an improvement of approximately 11% compared to the components that were not thermally treated.
Example lb: Repair of rough components in 357 aluminium-silicon alloy already subjected to complete thermal treatment of solubilisation and precipitation (ageing).
The mechanical resistance of the 357 aluminium-silicon alloy completely thermally treated, measured on cylindrical test pieces with diameter of 9.0 mm according to ASTM B557, is on average 307 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove with depth such as to reduce the resistant area to 33%
of the original area. The mean mechanical resistance measured on these test pieces was 122 MPa.
The test pieces with simulated defect were repaired by means of cold spray depositing a layer of 357 aluminium alloy powder with thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from
Analogous test pieces repaired by cold spray and subjected, after repair, to thermal solubilisation treatment at 540 C for 17.5 hours with cooling in water, followed by thermal treatment of precipitation (ageing) at 200 C for 7 hours, showed a mean mechanical resistance of 250 MPa, with an improvement of approximately 11% compared to the components that were not thermally treated.
Example lb: Repair of rough components in 357 aluminium-silicon alloy already subjected to complete thermal treatment of solubilisation and precipitation (ageing).
The mechanical resistance of the 357 aluminium-silicon alloy completely thermally treated, measured on cylindrical test pieces with diameter of 9.0 mm according to ASTM B557, is on average 307 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove with depth such as to reduce the resistant area to 33%
of the original area. The mean mechanical resistance measured on these test pieces was 122 MPa.
The test pieces with simulated defect were repaired by means of cold spray depositing a layer of 357 aluminium alloy powder with thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from
11 the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the mechanical resistance measured on the repaired test pieces was on average 197 MPa.
After repair by cold spray, a theimal treatment of solubilisation was performed at 540 C for 17.5 hours with cooling in water, followed by thermal treatment of precipitation (ageing) at 200 C for 7 hours; these treatments increased the mechanical characteristics of the repaired test pieces to mean values of 216 MPa, with an improvement also in this case of approximately 10-% with respect to the components that did not undergo the thermal treatment.
Example 2a: Repair of rough non-treated (as-cast) components in 357 aluminium-silicon alloy.
The mechanical resistance of the non thermally treated (as-cast) 357 aluminium-silicon alloy, measured on cylindrical test pieces with diameter 9.0 mm according to ASTM B557, is on average 199 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove with depth such as to reduce the resistant area to 49 of the original area. The mean mechanical resistance measured on these test pieces was 116 MPa.
The test pieces with simulated defect were repaired by cold spray depositing a layer of 357 aluminium alloy powder with thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the mechanical resistance measured on the repaired test pieces was on average 127 MPa. Analogous test pieces repaired by cold spray and subjected, after repair, to a thermal solubilisation treatment at 540 C for 17.5 hours with cooling in water, followed by a thermal precipitation (ageing) treatment at 200 C for 7 hours, showed a mean
After repair by cold spray, a theimal treatment of solubilisation was performed at 540 C for 17.5 hours with cooling in water, followed by thermal treatment of precipitation (ageing) at 200 C for 7 hours; these treatments increased the mechanical characteristics of the repaired test pieces to mean values of 216 MPa, with an improvement also in this case of approximately 10-% with respect to the components that did not undergo the thermal treatment.
Example 2a: Repair of rough non-treated (as-cast) components in 357 aluminium-silicon alloy.
The mechanical resistance of the non thermally treated (as-cast) 357 aluminium-silicon alloy, measured on cylindrical test pieces with diameter 9.0 mm according to ASTM B557, is on average 199 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove with depth such as to reduce the resistant area to 49 of the original area. The mean mechanical resistance measured on these test pieces was 116 MPa.
The test pieces with simulated defect were repaired by cold spray depositing a layer of 357 aluminium alloy powder with thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the mechanical resistance measured on the repaired test pieces was on average 127 MPa. Analogous test pieces repaired by cold spray and subjected, after repair, to a thermal solubilisation treatment at 540 C for 17.5 hours with cooling in water, followed by a thermal precipitation (ageing) treatment at 200 C for 7 hours, showed a mean
12 mechanical resistance of 271 MPa, with an improvement of approximately 113% compared to the components that did not undergo the thermal treatment.
Example 2b: Repair of rough non-treated (as-cast) components in 357 aluminium-silicon alloy.
The mechanical resistance of the non thermally treated (as-cast) 357 aluminium-silicon alloy, measured on cylindrical test pieces with diameter 9.0 mm according to ASTM E557, is on average 199 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove with depth such as to reduce the resistant area to 33%
of the original area. The mean mechanical resistance measured on these test pieces was 75 MPa.
The test pieces with simulated defect were repaired by cold spray depositing a layer of 357 aluminium alloy powder with thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the mechanical resistance measured on the repaired test pieces was on average 78 MPa. Analogous test pieces repaired by cold spray and subjected, after repair, to thermal treatment of solubilisation at 540 C for 17.5 hours with cooling in water, followed by thermal treatment of precipitation (ageing) at 200 C for 7 hours, showed a mean mechanical resistance of 191 MPa, with an .improvement of approximately 145% compared to the components that did not undergo the thermal treatment.
The examples given above highlight the benefits of complete thermal treatment on rough components made of 357 aluminium alloy repaired by cold-spray depositing.
Example 2b: Repair of rough non-treated (as-cast) components in 357 aluminium-silicon alloy.
The mechanical resistance of the non thermally treated (as-cast) 357 aluminium-silicon alloy, measured on cylindrical test pieces with diameter 9.0 mm according to ASTM E557, is on average 199 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove with depth such as to reduce the resistant area to 33%
of the original area. The mean mechanical resistance measured on these test pieces was 75 MPa.
The test pieces with simulated defect were repaired by cold spray depositing a layer of 357 aluminium alloy powder with thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the mechanical resistance measured on the repaired test pieces was on average 78 MPa. Analogous test pieces repaired by cold spray and subjected, after repair, to thermal treatment of solubilisation at 540 C for 17.5 hours with cooling in water, followed by thermal treatment of precipitation (ageing) at 200 C for 7 hours, showed a mean mechanical resistance of 191 MPa, with an .improvement of approximately 145% compared to the components that did not undergo the thermal treatment.
The examples given above highlight the benefits of complete thermal treatment on rough components made of 357 aluminium alloy repaired by cold-spray depositing.
13 As mentioned previously, the complete thermal treatment of solubilisation and ageing can entail deformations of the component, and it is therefore generally applied to rough components (e.g. castings or semi-finished products) where the dimensional tolerances allow for the deformations induced by the thermal treatment.
If, on the other hand, the component to be repaired has limited dimensional tolerances which do not allow for potential deformations by the theimal treatment, the partially repaired component is advantageously suhjected to a thermal treatment comprising a single stress-relieving phase.
If the component to be repaired is obtained from Al-Si alloys, type 355, 356 or 357, the stress-relieving phase is preferably perfoLmed at a temperature from 80 C to 250 C, more preferably from 100 C to 200 C, for a time in the range between 3 and 10 hours.
If the component to be repaired is obtained from Al-Cu alloys, type 2014, 2618, 2024, the stress-relieving phase is preferably perfoLmed at a temperature from 80 C to 200 C, more preferably from 100 C to 180 C, for a time in the range between 3 and 20 hours.
Some examples are given below of the advantages that can be obtained with application of only stress-relieving theimal treatment on test pieces made of 357 aluminium-silicon alloy repaired by cold spray using 357 aluminium-silicon alloy powder as supplied material:
Example 3a: Repair of semi-finished or finished components in 357 aluminium-silicon alloy already subjected to complete thermal treatment of solubilisation and precipitation (ageing).
The mechanical resistance of the 357 aluminium-silicon alloy completely thermally treated, measured on cylindrical test pieces
If, on the other hand, the component to be repaired has limited dimensional tolerances which do not allow for potential deformations by the theimal treatment, the partially repaired component is advantageously suhjected to a thermal treatment comprising a single stress-relieving phase.
If the component to be repaired is obtained from Al-Si alloys, type 355, 356 or 357, the stress-relieving phase is preferably perfoLmed at a temperature from 80 C to 250 C, more preferably from 100 C to 200 C, for a time in the range between 3 and 10 hours.
If the component to be repaired is obtained from Al-Cu alloys, type 2014, 2618, 2024, the stress-relieving phase is preferably perfoLmed at a temperature from 80 C to 200 C, more preferably from 100 C to 180 C, for a time in the range between 3 and 20 hours.
Some examples are given below of the advantages that can be obtained with application of only stress-relieving theimal treatment on test pieces made of 357 aluminium-silicon alloy repaired by cold spray using 357 aluminium-silicon alloy powder as supplied material:
Example 3a: Repair of semi-finished or finished components in 357 aluminium-silicon alloy already subjected to complete thermal treatment of solubilisation and precipitation (ageing).
The mechanical resistance of the 357 aluminium-silicon alloy completely thermally treated, measured on cylindrical test pieces
14 with diameter 9.0 mm according to ASTM 2557, is on average 307 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove of depth such as to reduce the resistant area to 49% of the original area. The mean mechanical resistance measured on these test pieces was 179 MPa.
The test pieces with simulated defect were repaired by cold spray depositing a layer of 357 aluminium alloy powder of thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the mechanical resistance measured on the repaired test pieces was on average 226 MPa. Analogous test pieces repaired by cold spray and subjected, after repair, to theLmal stress-relieving treatment at 125 C for 7 hours highlighted a mean mechanical resistance of 245 MPa, with an improvement of approximately 8% compared to the components that did not undergo the stress-relieving treatment.
Example 3b: Repair of semi-finished or finished components in 357 aluminium-silicon alloy already subjected to complete thermal treatment of solubilisation and precipitation (ageing).
The mechanical resistance of the 357 aluminium-silicon alloy completely theimally treated, measured on cylindrical test pieces with diameter 9.0 mm according to ASTM 2557, is on average 307 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove with depth such as to reduce the resistant area to 33% of the original area. The mean mechanical resistance measured on these test pieces was 122 MPa.
The test pieces with simulated defect were repaired by cold spray depositing a layer of 357 aluminium alloy with thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the 5 mechanical resistance measured on the repaired test pieces was on average 197 MPa. After repair by cold spray, the perfoLmance of subsequent thermal stress-relieving treatment at 125 C for 7 hours increased the mechanical characteristics of the repaired test pieces to mean values of 263 MPa, with an improvement of 33%
10 compared to the components that did not undergo the stress-relieving treatment.
The method of the invention has particularly positive effects on the repaired components in teLms of both improvement of the
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove of depth such as to reduce the resistant area to 49% of the original area. The mean mechanical resistance measured on these test pieces was 179 MPa.
The test pieces with simulated defect were repaired by cold spray depositing a layer of 357 aluminium alloy powder of thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the mechanical resistance measured on the repaired test pieces was on average 226 MPa. Analogous test pieces repaired by cold spray and subjected, after repair, to theLmal stress-relieving treatment at 125 C for 7 hours highlighted a mean mechanical resistance of 245 MPa, with an improvement of approximately 8% compared to the components that did not undergo the stress-relieving treatment.
Example 3b: Repair of semi-finished or finished components in 357 aluminium-silicon alloy already subjected to complete thermal treatment of solubilisation and precipitation (ageing).
The mechanical resistance of the 357 aluminium-silicon alloy completely theimally treated, measured on cylindrical test pieces with diameter 9.0 mm according to ASTM 2557, is on average 307 MPa.
To simulate a defect to be repaired, the working section of some test pieces was re-machined, creating a circumferential groove with depth such as to reduce the resistant area to 33% of the original area. The mean mechanical resistance measured on these test pieces was 122 MPa.
The test pieces with simulated defect were repaired by cold spray depositing a layer of 357 aluminium alloy with thickness sufficient to completely fill the circumferential groove. After removal of the excess layer from the working section of the test pieces, in order to restore the original diameter of 9.0 mm, the 5 mechanical resistance measured on the repaired test pieces was on average 197 MPa. After repair by cold spray, the perfoLmance of subsequent thermal stress-relieving treatment at 125 C for 7 hours increased the mechanical characteristics of the repaired test pieces to mean values of 263 MPa, with an improvement of 33%
10 compared to the components that did not undergo the stress-relieving treatment.
The method of the invention has particularly positive effects on the repaired components in teLms of both improvement of the
15 mechanical properties of the portion of supplied material and in terms of adhesion of the portion of supplied material to the substrate.
In particular, with the method of the invention the internal tensions in the portion of supplied material and at the interface with the substrate are reduced. Purtheimore, the hardening phases are precipitated, improving and stabilising the structure of the portion of supplied material which is thus made as far as possible uniform and similar to that of the substrate. At the same time, the method promotes the interdif fusion of lightweight elements at the interface, consequently improving adhesion between the portion of supplied material and the substrate.
In the condition in which the component to be repaired has sufficiently broad dimensional tolerances to allow for any defolmations introduced by the complete theimal treatment, the method of the invention has the particularly desirable effect, from the mechanical point of view and in terms of performance, of making the behaviour of the portion of supplied material very similar to that of the substrate. In fact, .the tensions due to the deformations inside the portion of supplied material are
In particular, with the method of the invention the internal tensions in the portion of supplied material and at the interface with the substrate are reduced. Purtheimore, the hardening phases are precipitated, improving and stabilising the structure of the portion of supplied material which is thus made as far as possible uniform and similar to that of the substrate. At the same time, the method promotes the interdif fusion of lightweight elements at the interface, consequently improving adhesion between the portion of supplied material and the substrate.
In the condition in which the component to be repaired has sufficiently broad dimensional tolerances to allow for any defolmations introduced by the complete theimal treatment, the method of the invention has the particularly desirable effect, from the mechanical point of view and in terms of performance, of making the behaviour of the portion of supplied material very similar to that of the substrate. In fact, .the tensions due to the deformations inside the portion of supplied material are
16 completely annulled and the material substantially re-precipitates in the precipitation (ageing) phase, thus obtaining the maximum benefit in terms of mechanical characteristics and adhesion between the parts.
In any case, even when the component to be repaired has limited dimensional tolerances which do not allow for ,potential deformations caused by thermal treatment, or because it has already been thermally treated before the repair, the method of the invention produces a significant benefit. In fact, the thermal stress-relieving treatment is perfoLmed at temperatures and for times such as to favour a sort of ageing of the material, but not such as to cause phenomena of over-precipitation, which would result in unacceptable. deterioration in the characteristics of the substrate base material.
With the treatment of the invention, in fact, the tensions inside the portion of supplied material are reduced and a precipitation of hardening phases is provoked in the same, thus minimising the differences with respect to the substrate base material (or the component to be repaired).
It should be noted that, on the basis of the previous studies performed on depositing of aluminium alloys by cold spray, such as those reported in the patent US 2009/0148622, it would appear not necessary to carry out theLuial treatments after the depositing to obtain the required mechanical properties.
Nevertheless, the method proposed in the present invention provides an undoubted improvement in the mechanical properties of the components.
The patent US 6,905,728 cites the performance, after repair of high pressure turbine components by cold spray, of a process of vacuum sintering, followed by a process of hot isostatic pressing and then thermal treatment. It is evident that said thermal treatment has the main objective of restoring the properties of
In any case, even when the component to be repaired has limited dimensional tolerances which do not allow for ,potential deformations caused by thermal treatment, or because it has already been thermally treated before the repair, the method of the invention produces a significant benefit. In fact, the thermal stress-relieving treatment is perfoLmed at temperatures and for times such as to favour a sort of ageing of the material, but not such as to cause phenomena of over-precipitation, which would result in unacceptable. deterioration in the characteristics of the substrate base material.
With the treatment of the invention, in fact, the tensions inside the portion of supplied material are reduced and a precipitation of hardening phases is provoked in the same, thus minimising the differences with respect to the substrate base material (or the component to be repaired).
It should be noted that, on the basis of the previous studies performed on depositing of aluminium alloys by cold spray, such as those reported in the patent US 2009/0148622, it would appear not necessary to carry out theLuial treatments after the depositing to obtain the required mechanical properties.
Nevertheless, the method proposed in the present invention provides an undoubted improvement in the mechanical properties of the components.
The patent US 6,905,728 cites the performance, after repair of high pressure turbine components by cold spray, of a process of vacuum sintering, followed by a process of hot isostatic pressing and then thermal treatment. It is evident that said thermal treatment has the main objective of restoring the properties of
17 the material after the sintering and hot isostatic pressing processes rather than that of improving the characteristics of the material deposited by cold spray.
Lastly, the publication "Characterization of low pressure type cold spray aluminium coatings" by K. Ogawa, K. Ito, K. Ichimura, Y. Ichikawa and T. Shoji, Sendai/J explicitly cites the beneficial effect of an annealing treatment at 270 C for 9 hours on the ductility of the aluminium deposit applied by cold spray.
However, although this thermal treatment improves the ductility of the material, it has the drawback of drastically reducing the mechanical properties of the substrate and therefore cannot be conveniently used in practice in the sector of interest taken into consideration for the present invention.
Lastly, the publication "Characterization of low pressure type cold spray aluminium coatings" by K. Ogawa, K. Ito, K. Ichimura, Y. Ichikawa and T. Shoji, Sendai/J explicitly cites the beneficial effect of an annealing treatment at 270 C for 9 hours on the ductility of the aluminium deposit applied by cold spray.
However, although this thermal treatment improves the ductility of the material, it has the drawback of drastically reducing the mechanical properties of the substrate and therefore cannot be conveniently used in practice in the sector of interest taken into consideration for the present invention.
Claims (7)
1. A method for repairing a precipitation hardened aluminium alloy component comprising the steps of:
a) cold spray depositing on said component to be repaired a portion of supplied material having a composition identical to that of said component to be repaired, thus obtaining a partially repaired component;
b) subjecting said partially repaired component to a thermal treatment, thus obtaining a repaired component, the conditions for performing said thermal treatment being selected as a function of the composition and of dimension tolerances of said component, characterised in that said step b) of thermal treatment comprises:
c) a first step of solubilisation followed by cooling in water;
and d) a second step, following the first step c), of precipitation.
a) cold spray depositing on said component to be repaired a portion of supplied material having a composition identical to that of said component to be repaired, thus obtaining a partially repaired component;
b) subjecting said partially repaired component to a thermal treatment, thus obtaining a repaired component, the conditions for performing said thermal treatment being selected as a function of the composition and of dimension tolerances of said component, characterised in that said step b) of thermal treatment comprises:
c) a first step of solubilisation followed by cooling in water;
and d) a second step, following the first step c), of precipitation.
2. The method according to claim 1, wherein, if said component to be repaired is obtained from type 355, 356 or 357 Al-Si alloys, said first step c) of solubilisation is performed at a temperature from 500°C to 580°C for a time in the range between 6 and 20 hours, and said second step d) of precipitation is performed at a temperature from 1000C to 300°C for a time in the range between 3 and 12 hours.
3. The method according to claim 2, wherein, if said component to be repaired is obtained from type 355, 356 or 357 Al-Si alloys, said first step c) of solubilisation is performed at a temperature from 530°C to 550°C for a time in the range between 6 and 20 hours, and said second step d) of precipitation is performed at a temperature from 150°C to 230°C for a time in the range between 3 and 12 hours.
4. The method according to claim 1, wherein, if said component to be repaired is obtained from type 2014, 2618 or 2024 Al-Si alloys, said first step c) of solubilisation is performed at a temperature from 400°C to 600°C for a time in the range between 1 and 3 hours;
said second step of precipitation is performed at a temperature from 150°C to 250°C for a time in the range between 8 and 20 hours.
said second step of precipitation is performed at a temperature from 150°C to 250°C for a time in the range between 8 and 20 hours.
5. The method according to claim 4, wherein, if said component to be repaired is obtained from type 2014, 2618 or 2024 Al-Si alloys, said first step c) of solubilisation is performed at a temperature from 460°C to 535°C for a time in the range between 1 and 3 hours;
said second step of precipitation is performed at a temperature from 160°C to 200°C for a time in the range between 8 and 20 hours.
said second step of precipitation is performed at a temperature from 160°C to 200°C for a time in the range between 8 and 20 hours.
6. A method for repairing a precipitation hardened aluminium alloy component obtained from type 355, 356 or 357 Al-Si alloys comprising the steps of:
a) cold spray depositing on said precipitation hardened 355, 356 or 357 Al-Si alloy component to be repaired a portion of supplied material having a composition identical to that of said precipitation hardened 355, 356 or 357 Al-Si alloy component to be repaired, thus obtaining a partially repaired precipitation hardened 355, 356 or 357 Al-Si alloy component;
b) subjecting said partially repaired precipitation hardened 355, 356 or 357 Al-Si alloy component to a thermal treatment, thus obtaining a repaired precipitation hardened 355, 356 or 357 Al-Si alloy component, the conditions for performing said thermal treatment being selected as a function of the composition and of dimension tolerances of said precipitation hardened 355, 356 or 357 Al-Si alloy component, wherein step b) of thermal treatment comprises a step e) of stress relieving performed at a temperature from 100°C to 200°C
for a time from 3 to 10 hours.
a) cold spray depositing on said precipitation hardened 355, 356 or 357 Al-Si alloy component to be repaired a portion of supplied material having a composition identical to that of said precipitation hardened 355, 356 or 357 Al-Si alloy component to be repaired, thus obtaining a partially repaired precipitation hardened 355, 356 or 357 Al-Si alloy component;
b) subjecting said partially repaired precipitation hardened 355, 356 or 357 Al-Si alloy component to a thermal treatment, thus obtaining a repaired precipitation hardened 355, 356 or 357 Al-Si alloy component, the conditions for performing said thermal treatment being selected as a function of the composition and of dimension tolerances of said precipitation hardened 355, 356 or 357 Al-Si alloy component, wherein step b) of thermal treatment comprises a step e) of stress relieving performed at a temperature from 100°C to 200°C
for a time from 3 to 10 hours.
7. A method for repairing a precipitation hardened aluminium alloy component obtained from type 2618 Al-Si alloys comprising the steps of:
a) cold spray depositing on said precipitation hardened 2618 Al-Si alloy component to be repaired a portion of supplied material having a composition identical to that of said precipitation hardened 2618 Al-Si alloy component to be repaired, thus obtaining a partially repaired precipitation hardened 2618 Al-Si alloy component;
b) subjecting said partially repaired precipitation hardened 2618 Al-Si m alloy component to a thermal treatment, thus obtaining a repaired precipitation hardened 2618 Al-Si alloy component, the conditions for performing said thermal treatment being selected as a function of the composition and of dimension tolerances of said precipitation hardened 2618 Al-Si alloy component, wherein step b) of thermal treatment comprises a step e) of stress relieving performed at a temperature from 100°C to 180°C for a time from 3 to 20 hours.
a) cold spray depositing on said precipitation hardened 2618 Al-Si alloy component to be repaired a portion of supplied material having a composition identical to that of said precipitation hardened 2618 Al-Si alloy component to be repaired, thus obtaining a partially repaired precipitation hardened 2618 Al-Si alloy component;
b) subjecting said partially repaired precipitation hardened 2618 Al-Si m alloy component to a thermal treatment, thus obtaining a repaired precipitation hardened 2618 Al-Si alloy component, the conditions for performing said thermal treatment being selected as a function of the composition and of dimension tolerances of said precipitation hardened 2618 Al-Si alloy component, wherein step b) of thermal treatment comprises a step e) of stress relieving performed at a temperature from 100°C to 180°C for a time from 3 to 20 hours.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IT000257A ITTO20110257A1 (en) | 2011-03-24 | 2011-03-24 | METHOD FOR REPAIRING AN ALUMINUM ALLOY COMPONENT |
| ITTO2011A000257 | 2011-03-24 | ||
| PCT/IB2012/051434 WO2012127457A1 (en) | 2011-03-24 | 2012-03-26 | Method for repairing an aluminium alloy component |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2830998A1 CA2830998A1 (en) | 2012-09-27 |
| CA2830998C true CA2830998C (en) | 2019-04-02 |
Family
ID=43977491
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2830998A Expired - Fee Related CA2830998C (en) | 2011-03-24 | 2012-03-26 | Method for repairing an aluminium alloy component |
Country Status (6)
| Country | Link |
|---|---|
| US (1) | US20140127400A1 (en) |
| EP (1) | EP2688708B1 (en) |
| CA (1) | CA2830998C (en) |
| ES (1) | ES2551080T3 (en) |
| IT (1) | ITTO20110257A1 (en) |
| WO (1) | WO2012127457A1 (en) |
Families Citing this family (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9335296B2 (en) | 2012-10-10 | 2016-05-10 | Westinghouse Electric Company Llc | Systems and methods for steam generator tube analysis for detection of tube degradation |
| WO2016115248A1 (en) | 2015-01-16 | 2016-07-21 | Sikorsky Aircraft Corporation | Cold spray method to join or in certain cases strengthen metals |
| US10569459B2 (en) * | 2016-04-23 | 2020-02-25 | Robotic Research, Llc | Handheld 3D printer |
| CN106939421A (en) * | 2017-02-16 | 2017-07-11 | 中国船舶重工集团公司第七二五研究所 | A kind of low pressure cold spray repairing method of Al-alloy casing |
| US11935662B2 (en) | 2019-07-02 | 2024-03-19 | Westinghouse Electric Company Llc | Elongate SiC fuel elements |
| KR102523509B1 (en) | 2019-09-19 | 2023-04-18 | 웨스팅하우스 일렉트릭 컴퍼니 엘엘씨 | Apparatus and Method of Use for Performing In Situ Adhesion Testing of Cold Spray Deposits |
| CN111118435B (en) * | 2020-02-27 | 2021-10-01 | 广东省科学院新材料研究所 | Aluminum alloy and method for improving fretting wear resistance thereof |
| CN111926322A (en) * | 2020-06-24 | 2020-11-13 | 广东省新材料研究所 | Repairing method of magnesium-aluminum alloy structural part |
| CN114481118B (en) * | 2021-12-16 | 2023-11-10 | 中车工业研究院有限公司 | Method for repairing aluminum alloy by laser cladding in atmospheric environment |
Family Cites Families (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3871928A (en) * | 1973-08-13 | 1975-03-18 | Int Nickel Co | Heat treatment of nickel alloys |
| KR950703669A (en) * | 1992-10-05 | 1995-09-20 | 디터 크리스트, 게르하르트 퀼 | PROTECTION OF CHROMIUM-STEEL SUBSTRATES AGHINST CORROSIVE AND EROSIVE ATTACK AT TEMPERATURES UP TO ABOUT 500 ℃ |
| US6146477A (en) * | 1999-08-17 | 2000-11-14 | Johnson Brass & Machine Foundry, Inc. | Metal alloy product and method for producing same |
| US6905728B1 (en) * | 2004-03-22 | 2005-06-14 | Honeywell International, Inc. | Cold gas-dynamic spray repair on gas turbine engine components |
| US20060134320A1 (en) * | 2004-12-21 | 2006-06-22 | United Technologies Corporation | Structural repair using cold sprayed aluminum materials |
| US7367488B2 (en) * | 2005-05-10 | 2008-05-06 | Honeywell International, Inc. | Method of repair of thin wall housings |
| US20060283920A1 (en) * | 2005-06-17 | 2006-12-21 | Siemens Westinghouse Power Corporation | Vibration stress relief of superalloy components |
| DE102006009751A1 (en) * | 2006-03-02 | 2007-09-06 | Praxair Surface Technologies Gmbh | Repairing and re-manufacturing dynamically-stressed aluminum alloy components for aircraft or aerospace applications, adds fatigue-resistant coating by cold-spraying |
| EP1829988A1 (en) * | 2006-03-02 | 2007-09-05 | Praxair Surface Technologies GmbH | Method of repairing and refurbishing an aluminum component under dynamic loading for airfoil equipments |
| US20090249603A1 (en) * | 2008-04-08 | 2009-10-08 | Chris Vargas | Cold deposition repair of casting porosity |
| US20090260724A1 (en) * | 2008-04-18 | 2009-10-22 | United Technologies Corporation | Heat treatable L12 aluminum alloys |
| KR100867277B1 (en) * | 2008-05-30 | 2008-11-06 | (주) 신우금형 | Method for repairing tire mold using cold spray technology |
| US20100155251A1 (en) * | 2008-12-23 | 2010-06-24 | United Technologies Corporation | Hard anodize of cold spray aluminum layer |
| US8486249B2 (en) * | 2009-01-29 | 2013-07-16 | Honeywell International Inc. | Cold spray and anodization repair process for restoring worn aluminum parts |
| CA2771585C (en) * | 2009-09-04 | 2015-11-24 | Alcoa Inc. | Methods of aging aluminum alloys to achieve improved ballistics performance |
-
2011
- 2011-03-24 IT IT000257A patent/ITTO20110257A1/en unknown
-
2012
- 2012-03-26 WO PCT/IB2012/051434 patent/WO2012127457A1/en active Application Filing
- 2012-03-26 EP EP12720582.1A patent/EP2688708B1/en active Active
- 2012-03-26 US US14/006,915 patent/US20140127400A1/en not_active Abandoned
- 2012-03-26 CA CA2830998A patent/CA2830998C/en not_active Expired - Fee Related
- 2012-03-26 ES ES12720582.1T patent/ES2551080T3/en active Active
Also Published As
| Publication number | Publication date |
|---|---|
| ES2551080T3 (en) | 2015-11-16 |
| EP2688708B1 (en) | 2015-08-19 |
| CA2830998A1 (en) | 2012-09-27 |
| ITTO20110257A1 (en) | 2012-09-25 |
| US20140127400A1 (en) | 2014-05-08 |
| EP2688708A1 (en) | 2014-01-29 |
| WO2012127457A1 (en) | 2012-09-27 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA2830998C (en) | Method for repairing an aluminium alloy component | |
| RU2731275C2 (en) | Method and device for production of part by successive application of layers | |
| US7479299B2 (en) | Methods of forming high strength coatings | |
| US10626974B2 (en) | Structured material alloy component fabrication | |
| CN107723699B (en) | Method for repairing heat-resistant alloy | |
| JP6291693B2 (en) | Mold correction and regeneration method using high-speed flame spray coating method and plasma ion nitriding method, and system thereof | |
| CN101054667B (en) | Material for repairing high-hardness engine member abandonment die by laser and application thereof | |
| JP2011508715A (en) | Highly mechanically required parts and special tool manufacturing methods from low cost ceramics or polymers such as concrete by casting into the desired shape and then coating with a metal or high performance ceramic layer | |
| WO2014116256A1 (en) | Solid state metal powder consolidation for structural components | |
| CN104561994A (en) | Laser surface cladding method for copper roller of metal belt forming machine | |
| EP3357605B1 (en) | Manufacturing method and post-processing treatment | |
| KR101722239B1 (en) | Surface treatment method using thermal spray coating and ultrasonic nanocrystal surface modification | |
| CN109252161A (en) | A kind of laser frit repair in carbon quenched and tempered steel defect method | |
| EP2564980A2 (en) | Solid state system and method for refurbishment of forged components | |
| RU2619419C2 (en) | Application method of titanium aluminide and product with titanium aluminide surface | |
| CN107805809A (en) | A kind of automobile die surface coating renovation technique | |
| CN101054668A (en) | Alloy powder for repairing engine member abandonment die by laser, application method and application thereof | |
| US20180361478A1 (en) | Processing method | |
| CN114686793B (en) | High-compactness nickel-based completely amorphous coating and preparation method thereof | |
| CN110424005A (en) | A kind of metalwork surface plasma cladding method easy to wear | |
| CN112548104B (en) | Method for reducing hot cracking sensitivity in die steel laser additive repair process | |
| JPH03264705A (en) | Repairing method for gas turbine moving blade | |
| CN114769585B (en) | Cold spray forming method of Cu-Cr-Nb alloy | |
| CN111004991A (en) | Preparation method of high-wear-resistance and high-corrosion-resistance protective layer of hot work die steel | |
| US20100266760A1 (en) | Process for the production of a coated plasticising screw |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request |
Effective date: 20170308 |
|
| MKLA | Lapsed |
Effective date: 20210326 |