WO2013070573A1 - Method of joining or repairing superalloy structures using projection resistance brazing : corresponding superalloy component - Google Patents
Method of joining or repairing superalloy structures using projection resistance brazing : corresponding superalloy component Download PDFInfo
- Publication number
- WO2013070573A1 WO2013070573A1 PCT/US2012/063658 US2012063658W WO2013070573A1 WO 2013070573 A1 WO2013070573 A1 WO 2013070573A1 US 2012063658 W US2012063658 W US 2012063658W WO 2013070573 A1 WO2013070573 A1 WO 2013070573A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- splice
- substrate
- recess
- brazing alloy
- contact surface
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K1/00—Soldering, e.g. brazing, or unsoldering
- B23K1/0004—Resistance soldering
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/002—Resistance welding; Severing by resistance heating specially adapted for particular articles or work
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/002—Resistance welding; Severing by resistance heating specially adapted for particular articles or work
- B23K11/004—Welding of a small piece to a great or broad piece
-
- 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
- B23K11/00—Resistance welding; Severing by resistance heating
- B23K11/14—Projection 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
- B23P6/005—Repairing turbine components, e.g. moving or stationary blades, rotors using only replacement pieces of a particular form
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/005—Repairing methods or devices
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/001—Turbines
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K2101/00—Articles made by soldering, welding or cutting
- B23K2101/04—Tubular or hollow articles
- B23K2101/06—Tubes
- B23K2101/08—Tubes finned or ribbed
-
- 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
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12451—Macroscopically anomalous interface between layers
Definitions
- the invention relates to structural joining of advanced superalloy components during fabrication and/or repair.
- the invention relates to surface repair of superalloy turbine blades and vanes in steam or gas turbines, by use of splice inserts that are affixed to a new or repaired substrate by projection resistance heat brazing under contact pressure, in a manner that does not significantly reduce mechanical structural or material properties of the joined components.
- a superalloy having more than 6% aggregate aluminum or titanium content such as CM247 alloy
- CM247 alloy is more susceptible to strain age cracking when subjected to high-temperature welding than a lower aluminum-titanium content X-750 superalloy.
- the finished turbine blade alloys are typically strengthened during post casting heat treatments which render them difficult to perform subsequent structural welding.
- Currently used welding processes for superalloy structural fabrication or repair generally involve
- cosmetic repair may be used in order to restore the repaired component's original profile geometry.
- an example of cosmetic repair is for filling surface pits (as opposed to structural cracks) on a turbine blade airfoil in order to restore its original aerodynamic profile, where the blade's localized exterior surface is not critical for structural integrity of the entire blade.
- Cosmetic repair or fabrication is often achieved by using oxidation resistant weld or braze alloys of lower strength than the blade body superalloy substrate, but having higher ductility and lower application
- brazing has been commonly used for cosmetic metal joining of common ferrous and non-ferrous (e.g., copper) alloys. As shown in FIG. 2, brazing is performed by passing current between compressed electrodes 22, 24 into a pair of abutting components 30, 32 Solid sheet, powder or paste brazing alloy 34 is interposed between the components 30, 32. As electric current is passed between the electrodes 22, 24 the brazing alloy 34 melts and affixes the common ferrous or non-ferrous alloy components 30, 32 to each other.
- the present inventor has no knowledge of past attempts to join
- an object of the invention is to perform structural joining or repairs on surfaces of superalloy components, such as turbine vanes and blades, so components can be joined; or that structural cracks and other surface defects can be repaired.
- Another object of the present invention is to increase the likelihood of performing successful structural repair of superalloy components, such as turbine vanes and blades, so that damaged component scrap rates can be reduced .
- Yet another object of the present invention is to perform structural fabrication or repair of superalloy components, such as turbine blades or vanes, with proven, repeatable repair techniques and machinery that do not require complex welding or post-repair heat treatment procedures .
- repair embodiments by structurally joining superalloy components, or repairing defects in superalloy material components, such as turbine blades or vanes.
- the surface defect is removed from the component substrate by electric discharge machining or other known metal working process, forming an excavated recess.
- a repair splice is formed, preferably of a same material with similar mechanical structural properties, having a mating projection with profile conforming to the corresponding recess profile.
- the repair splice is inserted and captured within the recess so that they abut each other along a contact surface.
- the splice and substrate are resistance heated under compression pressure until melting of braze alloy occurs along the contact surface, so that they are mutually affixed.
- a repair alloy braze must be interposed between the splice and recess substrate prior to resistance heating.
- the present invention features a joined superalloy component including a superalloy substrate defining a recess having a recess profile; and a mating superalloy splice having a splice projection captured within the substrate recess, with a projection profile conforming with the substrate profile along a contact surface within the recess.
- the substrate and splice are affixed to each other along the contact surface by the process of electric resistance brazing by interposing brazing alloy between the recess and repair splice along the contact surface.
- the substrate and splice projection are compressed together along the contact surface at a selected pressure.
- the substrate and splice are contacted with separate conductive electric resistance brazing electrodes.
- the present invention features a method for joining superalloy structures by forming a recess in a superalloy component substrate having a recess profile defined by the remaining substrate; and forming a mating superalloy splice having a splice projection, with a projection profile conforming with the substrate recess profile along a corresponding contact surface.
- Brazing alloy is interposed between the recess and repair splice along the contact surface.
- the splice is inserted and captured within the recess, so that the projection and recess are in abutting contact along the contact surface.
- the substrate and splice projection are compressed together along the contact surface at a selected pressure.
- the substrate and splice are in contact with separate conductive electric resistance brazing electrodes.
- Current is passed through the substrate and splice projection between the electrodes at a selected flow rate and application time period until brazing alloy localized melting occurs along the contact surface.
- Current flow ceases after the substrate and splice projection are mutually affixed to each other.
- the present invention also features a method for repairing a superalloy component by removing a damaged portion of superalloy component substrate and forming an excavated recess therein having a recess profile defined by the remaining substrate.
- a mating superalloy repair splice is formed, having a splice projection, with a projection profile conforming with the substrate recess profile along , corresponding contact surface.
- Brazing alloy is interposed between the recess and repair splice along the contact surface.
- the repair splice is inserted and captured within the recess, so that the projection and recess are in abutting contact along the contact surface.
- the substrate and splice projection are compressed together along the contact surface at a selected pressure with a pair of opposed electric resistance brazing electrodes. Current is passed through the substrate and splice projection between the electrodes at a selected flow rate and application time period until brazing alloy localized melting occurs along the contact surface and they are mutually affixed to each other .
- FIG. 1 is a chart showing superalloy strain age cracking susceptibility during welding, as a function of titanium and aluminum content in the alloy;
- FIG. 2 is a schematic elevational view of prior art resistance heat brazing apparatus and methods
- FIG. 3 is a schematic elevational view of a superalloy component having a surface defect in need of repair ;
- FIG. 4 is a schematic elevational view of a surface defect in a superalloy component being repaired in accordance with an embodiment of the present invention by excavating a damaged portion thereof;
- FIG. 5 is a schematic elevational view of a surface defect in a superalloy component being repaired in accordance with an embodiment of the present invention by replacing the damaged portion and replacing it with a repair splice ;
- FIG. 6 is a schematic elevational view of a surface defect in a superalloy component being repaired in accordance with an embodiment of the present invention by affixing the repair splice to the component substrate by resistance heating the repair splice and substrate;
- FIG. 7 is a detailed schematic elevational view of the resistance heating interface of FIGs . 6 and7; and [0034] FIG. 8 is a schematic elevational view of a superalloy component repaired in accordance with an
- teachings of the present invention can be readily utilized for structural repair of superalloy material turbine blades and vanes of the type used in steam or gas turbines, by use of splice inserts, in a manner that does not significantly reduce mechanical structural or material properties of the joined or repaired blade.
- the damage is removed, forming an excavated recess.
- a repair splice is formed of a same material with similar mechanical structural properties, having a mating outer profile conforming to the corresponding recess profile.
- the repair splice is inserted and captured within the recess, so that the blade body and repair splice are in abutting contact along a contact surface.
- the splice and abutting substrate are compressed under pressure and locally heated with an electric
- the repair methods of the present invention do not require complex brazing, welding or heat treatment procedures, and use known electric resistance heating brazing equipment and affixation processes.
- the joining methods of the present invention may be used to fabricate superalloy structures by joining subcomponents.
- FIG. 3 shows an exemplary superalloy component 40 having surface stress cracks 42. If the stress cracks are not structurally repaired (i.e., by mere cosmetic repair with relatively softer, lower application temperature welding or brazing alloys) there is a possibility that the cosmetically repaired cracks will re-crack and/or continue to spread within the component substrate.
- the recess 44 profile is defined by the remaining margins of the uncracked substrate 40. While a trapezoidal cross-sectional profile recess 44 is shown in FIG. 4, other cross-sectional profile configurations may be utilized, such as vee-shaped or arcuate-shaped profiles formed by cutting tool heads or EDM.
- the recess length (normal dimension in and out of the figure) may be varied. Suitable plan view profiles for recess 44 include circular symmetrical, square and
- the present invention differs from prior known replacement of superalloy material in cracks or formed recesses by inserting a repair splice 50, preferably constructed of the same superalloy material with similar material properties as the repaired component, as shown in FIG. 5.
- the repair splice 50 has a projecting portion 52 with a profile that conforms and mates with the recess profile 44.
- new subcomponents having mating projection and recess portions may be joined to fabricate a new component by the same method.
- a bonding filler braze alloy 60 must be interposed between the mating recess 44 and projection 52 to aid their respective joining during subsequent resistance heating processes.
- Filler alloy is chosen for compatibility with the chosen resistance heating bonding/j oining process.
- brazing filler alloy having a lower melting temperature than the superalloy substrate 40 and repair splice 50, is chosen for brazing processes.
- Welding filler alloys likely will have higher melting temperatures.
- powdered bonding filler 60 is shown schematically in FIG. 5, other forms of known filler may be applied, including by way of non-limiting example solid preshaped/preformed ring, foil or ribbon filler, granular filler, filler presintered on the surface, or filler paste.
- Filler alloy dimensions may be varied to optimize resistance heating heat transfer flux concentration, in conjunction with current application rates and time, so that desired braze melting is achieved between the joined superalloy components 40, 50.
- Known flux agents and/or activators e.g., borane-dimethylamine
- the filler material may include superalloy material base metals of the type used to construct the superalloy components.
- repair splice 50 and component substrate 40 are compressed relative to each other, with pressure being concentrated along the contact surface 62.
- a known type of resistance brazing heater 20' passes current between electrodes 22', 24', with heat transfer being concentrated along the contact surface
- a continuous seam weld longer than the electrode 22', 24' surface area can be formed by using longer, linear electrodes, rolling wheel electrode ( s ) , a plurality of proximal electrodes oriented in an array or moving the electrodes serially relative to the superalloy substrates 40, 50.
- multiple recesses 44 and projecting portions 52 may be formed in superalloy
- a suitable recess 44 profile depth d to width W ratio is 1:3.
- component 40 can be transferred across the contact surface to the splice, due to their mechanically and thermally abutting relationship. Relative affixation between the repaired component substrate 40 and the splice 50 along the contact surface 62 is sufficient to maintain structural integrity .
- the localized affixation along the contact surface 62 does not significantly negatively impact structural material properties of the repaired component substrate 40 and the splice 50. Limited post repair heat treatment (if any is required) minimizes-- if not totally eliminates-- subsequent risk of repaired component strain age cracking. Thus, time and expense of superalloy component fabrication or repair may be undertaken with the repair methods of the present invention, without undue risk of repair failure. In the power generation field, surface cracked turbine blades may be repaired without the need to scrap and replace them with new blades.
- Resistance heating oining/bonding may be carried out in ambient air, or alternatively in isolated vacuum, inert gas or active gas environments. As noted above, the resistance heating oining/bonding may be performed with filler alloy, flux and/or activator
- the overall objective is to achieve localized bonding between the superalloy subcomponents along the contact surface 62 and ceasing additional heat input, without significantly impacting the superalloy material properties within the generalized substrate of either subcomponent.
- the resistance heating application in the present invention avoids gross changes in the superalloy substrates - especially eliminating residual stresses associated with shrinkage typical during weld solidification.
- superalloy components can be joined or repaired with known proven equipment. Damaged superalloy component material can be removed and repair splices fabricated by electric discharge machining or other known metal cutting techniques . Known electric resistance heating brazing machinery and techniques may be employed to affix repair splices to their mating recesses. The splice-repaired superalloy component external surface profile can be restored to original profile
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Pressure Welding/Diffusion-Bonding (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA2854627A CA2854627A1 (en) | 2011-11-07 | 2012-11-06 | Method of joining or repairing superalloy structures using projection resistance brazing : corresponding superalloy component |
KR1020147015346A KR20140089587A (en) | 2011-11-07 | 2012-11-06 | Method of joining or repairing superalloy structures using projection resistance brazing : corresponding superalloy component |
JP2014541149A JP2014534079A (en) | 2011-11-07 | 2012-11-06 | Method of joining or repairing superalloy structures using resistance brazing of convex parts and corresponding superalloy components |
CN201280054605.8A CN103917320A (en) | 2011-11-07 | 2012-11-06 | Method of joining or repairing superalloy structures using projection resistance brazing : corresponding superalloy component |
EP12795159.8A EP2758203A1 (en) | 2011-11-07 | 2012-11-06 | Method of joining or repairing superalloy structures using projection resistance brazing : corresponding superalloy component |
MX2014005520A MX2014005520A (en) | 2011-11-07 | 2012-11-06 | Method of joining or repairing superalloy structures using projection resistance brazing : corresponding superalloy component. |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201161556391P | 2011-11-07 | 2011-11-07 | |
US61/556,391 | 2011-11-07 | ||
US13/352,475 US9186740B2 (en) | 2011-11-07 | 2012-01-18 | Projection resistance brazing of superalloys |
US13/352,475 | 2012-01-18 |
Publications (1)
Publication Number | Publication Date |
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WO2013070573A1 true WO2013070573A1 (en) | 2013-05-16 |
Family
ID=48223889
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2012/063658 WO2013070573A1 (en) | 2011-11-07 | 2012-11-06 | Method of joining or repairing superalloy structures using projection resistance brazing : corresponding superalloy component |
Country Status (8)
Country | Link |
---|---|
US (1) | US9186740B2 (en) |
EP (1) | EP2758203A1 (en) |
JP (1) | JP2014534079A (en) |
KR (1) | KR20140089587A (en) |
CN (1) | CN103917320A (en) |
CA (1) | CA2854627A1 (en) |
MX (1) | MX2014005520A (en) |
WO (1) | WO2013070573A1 (en) |
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2012
- 2012-01-18 US US13/352,475 patent/US9186740B2/en not_active Expired - Fee Related
- 2012-11-06 WO PCT/US2012/063658 patent/WO2013070573A1/en active Application Filing
- 2012-11-06 KR KR1020147015346A patent/KR20140089587A/en not_active Application Discontinuation
- 2012-11-06 EP EP12795159.8A patent/EP2758203A1/en not_active Withdrawn
- 2012-11-06 MX MX2014005520A patent/MX2014005520A/en unknown
- 2012-11-06 CA CA2854627A patent/CA2854627A1/en not_active Abandoned
- 2012-11-06 JP JP2014541149A patent/JP2014534079A/en active Pending
- 2012-11-06 CN CN201280054605.8A patent/CN103917320A/en active Pending
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Also Published As
Publication number | Publication date |
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CN103917320A (en) | 2014-07-09 |
US20130115477A1 (en) | 2013-05-09 |
KR20140089587A (en) | 2014-07-15 |
JP2014534079A (en) | 2014-12-18 |
EP2758203A1 (en) | 2014-07-30 |
MX2014005520A (en) | 2014-07-11 |
CA2854627A1 (en) | 2013-05-16 |
US9186740B2 (en) | 2015-11-17 |
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