US20120110848A1 - Low and extra low sulfur alloys for repair - Google Patents

Low and extra low sulfur alloys for repair Download PDF

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Publication number
US20120110848A1
US20120110848A1 US13/291,222 US201113291222A US2012110848A1 US 20120110848 A1 US20120110848 A1 US 20120110848A1 US 201113291222 A US201113291222 A US 201113291222A US 2012110848 A1 US2012110848 A1 US 2012110848A1
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United States
Prior art keywords
repair
refurbishment
replacement material
ppm
sulfur content
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US13/291,222
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Edward R. Szela
Daniel A. Bales
Alan D. Cetel
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Raytheon Technologies Corp
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United Technologies Corp
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Priority to US13/291,222 priority Critical patent/US20120110848A1/en
Assigned to UNITED TECHNOLOGIES CORPORATION reassignment UNITED TECHNOLOGIES CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BALES, DANIEL A., CETEL, ALAN D., SZELA, EDWARD R.
Publication of US20120110848A1 publication Critical patent/US20120110848A1/en
Priority to US15/211,238 priority patent/US10173291B2/en
Abandoned legal-status Critical Current

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    • 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
    • B23P6/04—Repairing fractures or cracked metal parts or products, e.g. castings
    • B23P6/045—Repairing fractures or cracked metal parts or products, e.g. castings of turbine components, e.g. moving or stationary blades, rotors, etc.
    • 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
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B23K10/027—Welding for purposes other than joining, e.g. 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
    • B23K26/34—Laser welding for purposes other than joining
    • 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
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or 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
    • 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 degrees 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 degrees C
    • B23K35/3046—Co 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
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding
    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/057—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being less 10%
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/07—Alloys based on nickel or cobalt based on cobalt
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • 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
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/01—Selective coating, e.g. pattern coating, without pre-treatment of the material to be coated
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment
    • 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
    • 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
    • F01D5/12—Blades
    • 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
    • F01D5/12—Blades
    • F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
    • F01D5/288—Protective coatings for blades
    • 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
    • F01D9/00—Stators
    • F01D9/02—Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
    • 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
    • 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
    • F05D2220/00—Application
    • F05D2220/30—Application in turbines
    • 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
    • F05D2230/31—Layer deposition
    • 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
    • F05D2230/40—Heat treatment
    • 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
    • F05D2230/80—Repairing, retrofitting or upgrading methods
    • 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
    • F05D2230/90—Coating; Surface treatment
    • 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
    • F05D2300/20—Oxide or non-oxide ceramics
    • F05D2300/22—Non-oxide ceramics
    • F05D2300/229—Sulfides
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49316—Impeller making
    • Y10T29/49318—Repairing or disassembling

Definitions

  • the present disclosure relates to a method for repairing/refurbishing/creating a turbine engine component or sub-component (e.g., a platform or vane) using a repair material which has sulfur in an amount less than 10 ppm.
  • a turbine engine component or sub-component e.g., a platform or vane
  • Turbine engine components such as turbine blades, or vanes occasionally have defects which require repair or refurbishment.
  • the defects may arise from the manufacture of the turbine engine component or may arise during the service life of the component.
  • different repair techniques have been used to repair such components.
  • oxidation occurs in the area of the repair after the repair has been effected.
  • repair of turbine components, such as vanes results in a reduction in oxidation life in crack or surface restoration areas where repair alloys are applied.
  • repair materials which help prevent the onset of oxidation in the repair area and which are capable of increasing oxidation life.
  • a method for repairing/refurbishing/creating a turbine engine component or sub-component which broadly comprises the steps of providing a turbine engine component/sub-component having a site to be repaired, providing a repair/refurbishment/replacement material having a sulfur content, which sulfur content is less than 10 ppm, and applying said repair/refurbishment/replacement material to the site on the turbine engine component to effect the repair/refurbishment/replacement.
  • a nickel based or a cobalt based repair/replacement material having sulfur which sulfur is present in an amount less than 10 ppm to improve oxidation life of the repaired turbine engine component or sub-component.
  • FIG. 1 is a flow chart showing a method for effecting a repair
  • FIGS. 2 and 3 are graphs showing a direct comparison of coated oxidation life of low sulfur PWA 1430 and PWA 1484;
  • FIGS. 4 and 5 are graphs showing a direct comparison of coated oxidation life of low sulfur PWA 1430 and PWA 1484.
  • FIG. 6 is a graph illustrating 2150° F. uncoated oxidation life vs. sulfur content.
  • the repair/refurbishment/replacement technique described herein is intended to improve the oxidation life of turbine engine components or sub-components repaired with materials, such as weld wire alloys, weld wire powders, powders used in powder bed machines (e.g., electron beam melting or laser sintering), and brazing materials, by controlling/reducing the level of sulfur in the repair/replacement material.
  • materials such as weld wire alloys, weld wire powders, powders used in powder bed machines (e.g., electron beam melting or laser sintering), and brazing materials.
  • sulfur levels below 10 ppm oxidation life can be improved.
  • sulfur levels are reduced below 7.0 ppm, oxidation life can be improved by up to 3 ⁇ over conventional sulfur levels.
  • the sulfur level in the repair material is less than 1.0 ppm.
  • Both nickel base and cobalt base alloy turbine components/sub-components could realize life improvement via control of the sulfur content of the material being used to repair/replace the turbine component/sub-component.
  • the sulfur control described herein could yield significant improvements in the oxidation of the life of components/sub-components built by or repaired by the use of additive manufacturing processes such as plasma powder deposition, laser cladding, powder bed equipment (e.g., electron beam melting or laser sintering), or gas metal arc deposition.
  • reductions in sulfur levels in the repair material could result in improved oxidation behavior of high pressure turbine blade tip repairs (a region of noted oxidation attack during engine service) and areas of surface restoration performed on components such as vanes or blades.
  • the turbine engine components/sub-components to be repaired/refurbished/created may be formed from alloys such as PWA 1455, PWA 1447, PWA 1422, PWA 1426, PWA 1484, PWA 647, PWA 1480, PWA 1440, PWA 655, Inconel 713, Rene 77, Rene 125, Rene 80, Rene 142, Rene N5, X-40, IN 100, CMSX-4, C1023 and MM002.
  • alloys such as PWA 1455, PWA 1447, PWA 1422, PWA 1426, PWA 1484, PWA 647, PWA 1480, PWA 1440, PWA 655, Inconel 713, Rene 77, Rene 125, Rene 80, Rene 142, Rene N5, X-40, IN 100, CMSX-4, C1023 and MM002.
  • a turbine engine component/sub-component to be repaired/replaced may be provided in step 100 .
  • Each site to be repaired/refurbished/replaced may be cleaned in step 102 . Any suitable cleaning technique known in the art may be used to remove deleterious material from the site(s) to be repaired and/or clean the site(s).
  • the repair/replacement material to be applied to the site to effect the repair or the refurbishment may be in the form of a weld wire alloy, a weld wire powder, a powder bed produced component/sub-component, or a repair alloy.
  • the weld wire alloy, the weld wire powder, powder bed produced component/sub-component, or repair alloy may be a nickel based or a cobalt based material.
  • nickel based means a material which has more than 50 wt % nickel and the term “cobalt based” means a material which has more than 50 wt % cobalt.
  • the repair/refurbishment/replacement material may be different from the material forming the turbine engine component.
  • the repair/refurbishment/replacement material contains sulfur; however, the sulfur content is less than 10 ppm and more than 0.001 ppm. It has been found to be desirable to maintain the sulfur content in the repair/refurbishment/replacement material in the range of from 0.5 ppm to 1.0 ppm.
  • the repair material used to effect the repair/refurbishment/replacement is applied to the site to be repaired/refurbished/replaced.
  • the repair material may be applied and the repair/refurbishment/replacement may be effected using any suitable technique known in the art.
  • the repair/replacement material may be applied using a welding technique such a gas tungsten arc welding or plasma arc welding, a brazing technique such as diffusing brazing and TURBOFIX® brazing, plasma powder deposition, laser cladding, or gas metal arc deposition. While the method has been described as being a repair method, it should be noted that the method described herein includes additive material restorations and component/sub-component replacements.
  • the turbine engine component with the applied repair/refurbishment/replacement material may be subjected to a heat treatment in step 106 if needed.
  • the heat treatment may be any suitable treatment known in the art.
  • FIGS. 2-5 there is shown a series of graphs which illustrate how a reduced sulfur content increases the oxidation life of alloy materials used for repairs in simulated engine exposure testing, i.e. burner rig.
  • FIGS. 2 and 3 illustrate a direct comparison of coated oxidation life of low sulfur PWAS 1430 and PWA 1484.
  • FIGS. 4 and 5 illustrate a direct comparison of coated oxidation life of low sulfur PWA 1430 and PWA 1484.
  • FIG. 6 there is shown a graph illustrating 2150° F. uncoated oxidation life vs. sulfur content. It can be seen that uncoated oxidation life at 2150° F. is strongly influenced by alloy sulfur content.

Abstract

A method for repairing, refurbishing, or replacing a turbine engine component or sub-component includes the steps of providing a turbine engine component or sub-component having a site to be repaired, refurbished, or replaced providing a repair or replacement material having a sulfur content, which sulfur content is less than 10 ppm, and applying the repair or replacement material to the site on the turbine engine component to effect the repair, the refurbishment, or the replacement.

Description

    CROSS REFERENCE TO RELATED APPLICATION(S)
  • The instant application claims the benefit of U.S. provisional patent application No. 61/411,072, filed Nov. 8, 2010, entitled LOW AND EXTRA LOW SULFUR ALLOYS FOR REPAIR.
    • BACKGROUND
  • The present disclosure relates to a method for repairing/refurbishing/creating a turbine engine component or sub-component (e.g., a platform or vane) using a repair material which has sulfur in an amount less than 10 ppm.
  • Turbine engine components, such as turbine blades, or vanes occasionally have defects which require repair or refurbishment. The defects may arise from the manufacture of the turbine engine component or may arise during the service life of the component. For many years, different repair techniques have been used to repair such components. Occasionally, oxidation occurs in the area of the repair after the repair has been effected. Similarly, repair of turbine components, such as vanes, results in a reduction in oxidation life in crack or surface restoration areas where repair alloys are applied.
  • Industry practice produces alloy weld wires and powders with sulfur levels specified from a minimum of 40 ppm to a maximum of 100 ppm.
  • It is desirable to use repair materials which help prevent the onset of oxidation in the repair area and which are capable of increasing oxidation life.
    • SUMMARY
  • It has been found that by controlling the amount of sulfur in the repair material, one may obtain marked improvements in oxidation life.
  • In accordance with the present disclosure, there is described a method for repairing/refurbishing/creating a turbine engine component or sub-component which broadly comprises the steps of providing a turbine engine component/sub-component having a site to be repaired, providing a repair/refurbishment/replacement material having a sulfur content, which sulfur content is less than 10 ppm, and applying said repair/refurbishment/replacement material to the site on the turbine engine component to effect the repair/refurbishment/replacement.
  • Further, in accordance with the present disclosure, there is provided a nickel based or a cobalt based repair/replacement material having sulfur, which sulfur is present in an amount less than 10 ppm to improve oxidation life of the repaired turbine engine component or sub-component.
  • Other details of the low and extra low sulfur alloys for repair/refurbishment/replacement are set forth in the following detailed description, wherein like reference numerals depict like elements.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a flow chart showing a method for effecting a repair;
  • FIGS. 2 and 3 are graphs showing a direct comparison of coated oxidation life of low sulfur PWA 1430 and PWA 1484;
  • FIGS. 4 and 5 are graphs showing a direct comparison of coated oxidation life of low sulfur PWA 1430 and PWA 1484; and
  • FIG. 6 is a graph illustrating 2150° F. uncoated oxidation life vs. sulfur content.
    •  DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • The repair/refurbishment/replacement technique described herein is intended to improve the oxidation life of turbine engine components or sub-components repaired with materials, such as weld wire alloys, weld wire powders, powders used in powder bed machines (e.g., electron beam melting or laser sintering), and brazing materials, by controlling/reducing the level of sulfur in the repair/replacement material. By controlling sulfur levels below 10 ppm, oxidation life can be improved. As sulfur levels are reduced below 7.0 ppm, oxidation life can be improved by up to 3× over conventional sulfur levels. Desirably, the sulfur level in the repair material is less than 1.0 ppm.
  • Both nickel base and cobalt base alloy turbine components/sub-components could realize life improvement via control of the sulfur content of the material being used to repair/replace the turbine component/sub-component. The sulfur control described herein could yield significant improvements in the oxidation of the life of components/sub-components built by or repaired by the use of additive manufacturing processes such as plasma powder deposition, laser cladding, powder bed equipment (e.g., electron beam melting or laser sintering), or gas metal arc deposition. In particular, reductions in sulfur levels in the repair material could result in improved oxidation behavior of high pressure turbine blade tip repairs (a region of noted oxidation attack during engine service) and areas of surface restoration performed on components such as vanes or blades.
  • The turbine engine components/sub-components to be repaired/refurbished/created may be formed from alloys such as PWA 1455, PWA 1447, PWA 1422, PWA 1426, PWA 1484, PWA 647, PWA 1480, PWA 1440, PWA 655, Inconel 713, Rene 77, Rene 125, Rene 80, Rene 142, Rene N5, X-40, IN 100, CMSX-4, C1023 and MM002.
  • In accordance with the method of the present invention, and as shown in FIG. 1, a turbine engine component/sub-component to be repaired/replaced may be provided in step 100. Each site to be repaired/refurbished/replaced may be cleaned in step 102. Any suitable cleaning technique known in the art may be used to remove deleterious material from the site(s) to be repaired and/or clean the site(s).
  • The repair/replacement material to be applied to the site to effect the repair or the refurbishment may be in the form of a weld wire alloy, a weld wire powder, a powder bed produced component/sub-component, or a repair alloy. The weld wire alloy, the weld wire powder, powder bed produced component/sub-component, or repair alloy may be a nickel based or a cobalt based material. As used herein, the term “nickel based” means a material which has more than 50 wt % nickel and the term “cobalt based” means a material which has more than 50 wt % cobalt. The repair/refurbishment/replacement material may be different from the material forming the turbine engine component. Most notably, the repair/refurbishment/replacement material contains sulfur; however, the sulfur content is less than 10 ppm and more than 0.001 ppm. It has been found to be desirable to maintain the sulfur content in the repair/refurbishment/replacement material in the range of from 0.5 ppm to 1.0 ppm.
  • As shown in step 104, the repair material used to effect the repair/refurbishment/replacement is applied to the site to be repaired/refurbished/replaced. The repair material may be applied and the repair/refurbishment/replacement may be effected using any suitable technique known in the art. For example, the repair/replacement material may be applied using a welding technique such a gas tungsten arc welding or plasma arc welding, a brazing technique such as diffusing brazing and TURBOFIX® brazing, plasma powder deposition, laser cladding, or gas metal arc deposition. While the method has been described as being a repair method, it should be noted that the method described herein includes additive material restorations and component/sub-component replacements.
  • Following application of the repair/refurbishment/replacement material, the turbine engine component with the applied repair/refurbishment/replacement material may be subjected to a heat treatment in step 106 if needed. The heat treatment may be any suitable treatment known in the art.
  • Referring now to FIGS. 2-5, there is shown a series of graphs which illustrate how a reduced sulfur content increases the oxidation life of alloy materials used for repairs in simulated engine exposure testing, i.e. burner rig. FIGS. 2 and 3 illustrate a direct comparison of coated oxidation life of low sulfur PWAS 1430 and PWA 1484. FIGS. 4 and 5 illustrate a direct comparison of coated oxidation life of low sulfur PWA 1430 and PWA 1484.
  • Referring now to FIG. 6, there is shown a graph illustrating 2150° F. uncoated oxidation life vs. sulfur content. It can be seen that uncoated oxidation life at 2150° F. is strongly influenced by alloy sulfur content.
  • It is apparent that there has been provided in accordance with the present disclosure low and extra low sulfur alloys for repairing, refurbishing, or replacing turbine engine components/sub-components. While the disclosure has been described in the context of specific embodiments thereof, other unforeseen alternatives, modifications, and variations may become apparent to those skilled in the art having read the foregoing description. Accordingly, it is intended to embrace those alternatives, modifications, and variations which fall within the broad scope of the appended claims.

Claims (17)

1. A method for repairing, refurbishing, or replacing a turbine engine component/sub-component comprising the steps of:
providing a turbine engine component/sub-component having a site to be repaired;
providing a repair/refurbishment/replacement material having a sulfur content, which sulfur content is less than 10 ppm; and
applying the repair/refurbishment/replacement material to the site on the turbine engine component to the site on the turbine engine component to effect said repair/refurbishment/replacement.
2. The method of claim 1, wherein said step of providing said repair/refurbishment/replacement material comprises providing a nickel based repair material having said sulfur content.
3. The method of claim 1, wherein said step of providing said repair/refurbishment/replacement material comprises providing a cobalt based repair material having said sulfur content.
4. The method of claim 1, wherein said step of providing said repair/refurbishment/replacement material comprises providing a repair/refurbishment/replacement material having said sulfur content below 7.0 ppm.
5. The method of claim 1, wherein said step of providing said repair/refurbishment/replacement material comprises providing a repair/refurbishment/replacement material having said sulfur content below 1.0 ppm.
6. The method of claim 1, wherein said step of providing said repair/refurbishment/replacement material comprises providing a repair/refurbishment/replacement material having said sulfur content in the range of from 0.5 ppm to 1.0 ppm.
7. The method of claim 1, wherein said step of providing said repair/refurbishment/replacement_material comprises providing a repair/refurbishment/replacement_material having said sulfur content in the range of from 0.001 ppm to less than 10 ppm.
8. The method of claim 1, wherein said applying step comprises applying said repair/refurbishment/replacement material using a technique selected from the group consisting of a welding technique, a brazing technique, a plasma powder deposition technique, a laser cladding technique, a powder bed produced component/sub-component, and a gas metal arc deposition technique.
9. The method of claim 1, further comprising subjecting said turbine engine component/sub-component with said applied repair/refurbishment/replacement material to a heat treatment.
10. A repair/refurbishment/replacement material comprising a base material selected from the group consisting of nickel and cobalt and having a sulfur content, said sulfur content being less than 10 ppm.
11. The repair/refurbishment/replacement material according to claim 10, wherein said base material is present in an amount more than 50 wt %.
12. The repair/refurbishment/replacement material according to claim 10, wherein said repair/refurbishment/replacement material comprises a nickel based alloy and said base material is nickel.
13. The repair/refurbishment/replacement material according to claim 10, wherein said repair/refurbishment/replacement material comprises a cobalt based alloy and said base material is cobalt.
14. The repair/refurbishment/replacement material of claim 10, wherein said repair/refurbishment/replacement material has said sulfur content below 7.0 ppm.
15. The repair/refurbishment/replacement material of claim 10, wherein said repair/refurbishment/replacement material has said sulfur content below 1.0 ppm.
16. The repair/refurbishment/replacement material of claim 10, wherein said repair/refurbishment/replacement material has said sulfur content in the range of from 0.5 ppm to 1.0 ppm.
17. The repair/refurbishment/replacement material of claim 10, wherein said repair/refurbishment/replacement material has said sulfur content in the range of from 0.001 ppm to less than 10 ppm.
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